Air cleaner assembly; components therefor; and, methods

ABSTRACT

Air filter cartridges for use in air cleaner assemblies are described. The air filter cartridges typically comprise a stack of strips of fluted media, having an inlet flow face and an outlet flow face. A projection is provided extending outwardly from adjacent the outlet flow face of the media pack, as a projection supporting a seal arrangement. The seal arrangement is typically rectangular, with four straight and four rounded corners. The projection can be configured with open corners, and in some instances comprises tabs, to facilitate flexing of the projection to accommodate variations in a housing seal surface, with which the cartridge is installed. Air cleaner assemblies and components therefor, using cartridges in accord with the descriptions herein, are described.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. Ser. No.14/293,023, filed Jun. 2, 2014. U.S. Ser. No. 14/293,023 is acontinuation of Ser. No. 12/737,519, filed Apr. 7, 2011, which issued asU.S. Pat. No. 8,741,017 on Jun. 3, 2014. U.S. Ser. No. 12/737,519 wasfiled as a National Stage of PCT International Patent ApplicationPCT/US2009/051214, filed Jul. 21, 2009. The present application includesthe disclosure of, with edits, U.S. provisional application 61/135,595filed Jul. 22, 2008. The complete disclosures of U.S. Ser. Nos.14/293,023; 12/737,519; PCT/US2009/051214 and, U.S. application61/135,595 are incorporated herein by reference. A claim of priority toeach of U.S. Ser. Nos. 14/293,023; 12/737,519; PCT/US2009/051214 and,U.S. application 61/135,595 is made, to the extent appropriate.

FIELD OF THE DISCLOSURE

The present disclosure relates to filter arrangements for use infiltering air. The disclosure particularly relates to filterarrangements including media packs that use media as characterizedherein. The media generally comprises flutes formed into a media packhaving inlet and outlet faces with flutes extending therebetween. Morespecifically, the disclosure relates to such use of media packs andtheir inclusion in serviceable air filter cartridges for use in aircleaners. Air cleaner arrangements and methods of assembly and use arealso described.

BACKGROUND

Air streams can carry contaminant material therein. In many instances,it is desired to filter some or all of the contaminant material from theair stream. For example, air flow streams to engines (for examplecombustion air) for motorized vehicles or for power generationequipment, gas streams to gas turbine systems and air streams to variouscombustion furnaces, carry particulate contaminant therein that shouldbe filtered. It is preferred for such systems, that selected contaminantmaterial be removed from (or have its level reduced in) the air. Avariety of air filter arrangements have been developed for contaminantrejection. Improvements are sought.

SUMMARY

According to the present disclosure, air cleaner assemblies andcomponents therefor are described. In the example systems depicted, aserviceable main filter cartridge is provided which comprises inlet andoutlet flow faces, with flutes of fluted media extending therebetween;the media pack being closed to flow of air entering the inlet face andpassing outwardly from the outlet flow face without filtering the flowthrough the media of the media pack. Example media packs are described,which comprise stacks of strips and fluted media.

A housing seal arrangement is positioned to project axially outwardlyfrom the outlet flow face, adjacent the outlet flow face. It isconfigured with a seal member having at least one of: a radially,inwardly directed housing seal; and, a radially, outwardly directedhousing seal. In addition, each radial side of the seal member isconfigured to engage a housing seal groove engagement surface, in an aircleaner housing with which the cartridge is to be used. Examplearrangements and alternatives therefor, are described.

An air cleaner assembly is depicted, for removable insertion therein ofan air filter cartridge as previously characterized. The housingincludes a seal groove therein, for receipt, projecting into the sealgroove, of the housing seal arrangement on the filter cartridge. Somespecific housing features are characterized.

There is no requirement than an assembly include all of the featurescharacterized herein, in order to obtain some benefit according to thepresent disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary, schematic, perspective view of z-filter mediauseable in arrangements according to the present disclosure.

FIG. 2 is an enlarged, schematic, cross-sectional view of a portion ofthe media depicted in FIG. 1.

FIG. 3 includes schematic views of examples of various fluted mediadefinitions.

FIG. 4 is a schematic view of an example process for manufacturing mediaaccording to the present disclosure.

FIG. 5 is a schematic cross-sectional view of an optional end dart formedia flutes useable in arrangements according to the presentdisclosure.

FIG. 6 is a schematic depiction of a step of creating a stacked z-filtermedia pack.

FIG. 7 is a schematic side elevational view of an air cleaner assemblyaccording to the present disclosure.

FIG. 8 is a schematic side elevational view of the air cleaner assemblyof FIG. 7, depicted with an access cover opened, for service access toan interior of the air cleaner assembly.

FIG. 9 is a schematic top plan view of the air cleaner assembly of FIG.7.

FIG. 10 is a schematic cross-sectional view taken generally along line10-10, FIG. 9, but depicting an access cover opened for service accessto an interior of the assembly.

FIG. 11 is a schematic, top, outlet end, perspective view of the aircleaner assembly of FIG. 7.

FIG. 12 is a schematic, top, inlet end, perspective view of the aircleaner assembly of FIG. 7.

FIG. 13 is a schematic outlet end elevational view of the air cleanerassembly of FIG. 7.

FIG. 14 is a schematic access cover end elevational view of the aircleaner assembly of FIG. 7.

FIG. 15 is a schematic bottom plan view of the air cleaner assembly ofFIG. 7.

FIG. 16 is a schematic cross-sectional view taken generally along line10-10, FIG. 7.

FIG. 17 is a schematic side elevational view of a housing component ofthe air cleaner of FIG. 7, with an access cover depicted in an openorientation.

FIG. 18 is a schematic perspective view of the housing of FIG. 17,depicted generally toward an interior thereof.

FIG. 19 is a schematic, inlet end, perspective view of a filtercartridge component of the air cleaner assembly of FIG. 7.

FIG. 20 is a schematic, outlet end, perspective view of the filtercartridge of FIG. 19.

FIG. 21 is a schematic, outlet end, plan view of the filter cartridge ofFIGS. 19 and 20.

FIG. 22 is a schematic side elevational view of the filter cartridge ofFIGS. 19-21.

FIG. 23 is a schematic cross-sectional view taken generally along line23-23, FIG. 21.

FIG. 24 is an enlarged, schematic, fragmentary view of an identifiedportion of FIG. 23.

FIG. 25 is a schematic cross-sectional view taken generally along line25-25, FIG. 21.

FIG. 26 is an enlarged, schematic, fragmentary view of a selectedportion of FIG. 25.

FIG. 27 is a schematic end elevational view of the filter cartridge ofFIGS. 19-21.

FIG. 28 is a schematic side elevational view analogous to FIG. 22, butdepicting the cartridge inverted relative to FIG. 22.

FIG. 29 is a schematic cross-sectional view taken generally along line29-29, FIG. 28.

FIG. 30 is an enlarged, schematic, fragmentary view of a selectedportion of FIG. 29; in FIG. 30, a fragmentary cross-sectional view of ahousing portion also being depicted.

FIG. 31 is an enlarged, fragmentary, schematic view of a selectedportion of FIG. 29.

FIG. 32 is a schematic outlet end plan view of the filter cartridge ofFIGS. 19 and 20.

FIG. 32A is a schematic cross-sectional view taken along line 32A-32A,FIG. 32.

FIG. 33 is an enlarged, schematic, fragmentary view of a selectedportion of FIG. 33, depicted inserted in a housing portion; also shownin schematic, fragmentary, view.

FIG. 34 is a schematic, outlet, perspective view of a shell component ofthe cartridge of FIGS. 19-21.

FIG. 35 is a schematic, inlet end, perspective view of the shellcomponent of FIG. 34.

FIG. 36 is a schematic side elevational view of the shell component ofFIGS. 34 and 35.

FIG. 37 is a schematic, enlarged, fragmentary view of an identifiedportion of FIG. 36.

FIG. 38 is a schematic, outlet, perspective view of the shell componentof FIGS. 34 and 35.

FIG. 39 is a schematic end elevational view of the shell component ofFIGS. 34 and 35.

FIG. 40 is a schematic enlarged fragmentary view of an identifiedportion of FIG. 39.

FIG. 41 is a second schematic, outlet, perspective view of the shellcomponent of FIG. 34; the view of FIG. 41 generally corresponding to theview of FIG. 38.

FIG. 42 is an a schematic, cross-sectional view taken along line 42-42,of FIG. 41.

FIG. 42A is an enlarged schematic, fragmentary view of a identifiedportion of FIG. 42.

FIG. 43 is an enlarged, schematic, fragmentary view of an identifiedportion of FIG. 41.

FIG. 44 is an enlarged schematic fragmentary view of a second identifiedportion of FIG. 41.

FIG. 45 is a schematic fragmentary inside view of a housing outlet endsection for the air cleaner of FIG. 7.

FIG. 46 is a schematic inside plan view of the housing outlet endsection of FIG. 45.

FIG. 47 is a schematic outside plan view of the housing outlet endsection of FIG. 45.

FIG. 48 is a schematic perspective view of a frame piece for a safetycartridge usable in the air cleaner assembly of FIG. 7.

FIG. 49 is a schematic side elevational view of a safety cartridge usingthe frame piece depicted in FIG. 48.

FIG. 50 is a schematic side elevational view of a first alternate filtercartridge usable in the air cleaner assembly of FIG. 7.

FIG. 51 is a schematic end elevational view of the cartridge depicted inFIG. 50.

FIG. 52 is a schematic cross-sectional view taken along line 52-52, FIG.50.

FIG. 53 is a schematic, outlet, plan view of the cartridge depicted inFIG. 50.

FIG. 54 is an enlarged schematic fragmentary view of an identifiedportion of FIG. 52.

FIG. 55 is a schematic, outlet, plan view of a second alternate filtercartridge, usable in the air cleaner assembly of FIG. 7.

FIG. 56 is a schematic cross-sectional view taken along line 56-56, FIG.55.

FIG. 57 is an enlarged, fragmentary, schematic view of a selectedidentified portion of FIG. 56.

FIG. 58 is schematic, inlet, perspective view of a third alternatefilter cartridge usable in the assembly of FIG. 7.

FIG. 59 is a schematic side elevational view of the cartridge depictedin FIG. 58.

FIG. 60 is a schematic cross-sectional view taken generally along line60-60, FIG. 59.

FIG. 61 is a schematic, outlet, plan view of the filter cartridge ofFIG. 58.

FIG. 62 is a schematic cross-sectional view taken generally along line62-62, FIG. 61.

FIG. 63 is an enlarged, schematic, fragmentary view of an identifiedportion of FIG. 62.

FIG. 64 is enlarged, schematic, fragmentary view of an identifiedportion of FIG. 60.

FIG. 65 is a schematic, end elevational view of the filter cartridge ofFIG. 58.

FIG. 66 is a schematic cross-sectional view taken generally along 66-66,FIG. 65.

FIG. 67 is schematic, enlarged, fragmentary view of a selectedidentified portion of FIG. 66.

DETAILED DESCRIPTION I. Media Configurations, Generally

Fluted filter media can be used to provide fluid filter constructions ina variety of manners. One well known manner is characterized herein as az-filter construction. The term “z-filter construction” as used herein,is meant to refer to a type of filter construction in which individualones of corrugated, folded or otherwise formed filter flutes are used todefine sets of longitudinal, typically parallel, inlet and outlet filterflutes for fluid flow through the media; the fluid flowing along thelength of the flutes between opposite inlet and outlet flow ends (orflow faces) of the media. Some examples of z-filter media are providedin U.S. Pat. Nos. 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574;6,210,469; 6,190,432; 6,350,296; 6,179,890; 6,235,195; Des. 399,944;Des. 428,128; Des. 396,098; Des. 398,046; and, Des. 437,401; each ofthese fifteen cited references being incorporated herein by reference.

One type of z-filter media, utilizes two specific media componentsjoined together, to form the media construction. The two components are:(1) a fluted (typically corrugated) media sheet; and, (2) a facing mediasheet. The facing media sheet is typically non-corrugated, however itcan be corrugated, for example perpendicularly to the flute direction asdescribed in U.S. provisional 60/543,804, filed Feb. 11, 2004, andpublished as PCT WO 05/077487 on Aug. 25, 2005, incorporated herein byreference.

The fluted (typically corrugated) media sheet and the facing media sheettogether, are used to define media having parallel inlet and outletflutes. In some instances, the fluted sheet and facing sheet are securedtogether and are then coiled to form a z-filter media construction. Sucharrangements are described, for example, in U.S. Pat. No. 6,235,195 andU.S. Pat. No. 6,179,890, each of which is incorporated herein byreference. In certain other arrangements, some non-coiled sections orstrips of fluted (typically corrugated) media secured to facing media,are stacked on one another, to create a filter construction. An exampleof this is described in FIG. 11 of U.S. Pat. No. 5,820,646, incorporatedherein by reference.

Herein, strips of material comprising fluted sheet secured to corrugatedsheet, which are then assembled into stacks to form media packs, aresometimes referred to as “single facer strips” or a “single facer”. Theterm “single facer strip”, and “single facer” and variants thereof, ismeant to refer to a fact that one face, i.e., a single face, of thefluted (typically corrugated) sheet, is faced by the facing sheet, ineach strip.

Typically, coiling of the fluted sheet/facing sheet (i.e., single facer)combination around itself, to create a coiled media pack, is conductedwith the facing sheet directed outwardly. Some techniques for coilingare described in U.S. provisional application 60/467,521, filed May 2,2003 and PCT Application U.S. 04/07927, filed Mar. 17, 2004, nowpublished as WO 04/082795, each of which is incorporated herein byreference. The resulting coiled arrangement generally has, as the outersurface of the media pack, a portion of the facing sheet, as a result.

The term “corrugated” used herein to refer to structure in media, ismeant to refer to a flute structure resulting from passing the mediabetween two corrugation rollers, i.e., into a nip or bite between tworollers, each of which has surface features appropriate to cause acorrugation affect in the resulting media. The term “corrugation” is notmeant to refer to flutes that are formed by techniques not involvingpassage of media into a bite between corrugation rollers. However, theterm “corrugated” is meant to apply even if the media is furthermodified or deformed after corrugation, for example by the foldingtechniques described in PCT WO 04/007054, published Jan. 22, 2004,incorporated herein by reference.

Corrugated media is a specific form of fluted media. Fluted media ismedia which has individual flutes (for example formed by corrugating orfolding) extending thereacross.

Serviceable filter element or filter cartridge configurations utilizingz-filter media are sometimes referred to as “straight through flowconfigurations” or by variants thereof. In general, in this context whatis meant is that the serviceable filter elements or cartridges generallyhave an inlet flow end (or face) and an opposite exit flow end (orface), with flow entering and exiting the filter cartridge in generallythe same straight through direction. The term “serviceable” in thiscontext is meant to refer to a media containing filter cartridge that isperiodically removed and replaced from a corresponding fluid (e.g. air)cleaner. In some instances, each of the inlet flow end (or face) andoutlet flow end (or face) will be generally flat or planar, with the twoparallel to one another. However, variations from this, for examplenon-planar faces, are possible.

A straight through flow configuration (especially for a coiled orstacked media pack) is, for example, in contrast to serviceable filtercartridges such as cylindrical pleated filter cartridges of the typeshown in U.S. Pat. No. 6,039,778, incorporated herein by reference, inwhich the flow generally makes a turn as its passes through theserviceable cartridge. That is, in a U.S. Pat. No. 6,039,778 filter, theflow enters the cylindrical filter cartridge through a cylindrical side,and then turns to exit through an end face (in forward-flow systems). Ina typical reverse-flow system, the flow enters the serviceablecylindrical cartridge through an end face and then turns to exit througha side of the cylindrical filter cartridge. An example of such areverse-flow system is shown in U.S. Pat. No. 5,613,992, incorporated byreference herein.

The term “z-filter media construction” and variants thereof as usedherein, without more, is meant to refer to any or all of: a web ofcorrugated or otherwise fluted media secured to (facing) media withappropriate sealing to allow for definition of inlet and outlet flutes;and/or a media pack constructed or formed from such media into a threedimensional network of inlet and outlet flutes; and/or, a filtercartridge or construction including such a media pack.

In FIG. 1, an example of media 1 useable in z-filter media is shown. Themedia 1 is formed from a fluted, in this instance corrugated, sheet 3and a facing sheet 4. A construction such as media 1 is deferred toherein as a single facer or single facer strip.

In general, the corrugated sheet 3, FIG. 1 is of a type generallycharacterized herein as having a regular, curved, wave pattern of flutesor corrugations 7. The term “wave pattern” in this context, is meant torefer to a flute or corrugated pattern of alternating troughs 7 b andridges 7 a. The term “regular” in this context is meant to refer to thefact that the pairs of troughs and ridges (7 b, 7 a) alternate withgenerally the same repeating corrugation (or flute) shape and size.(Also, typically in a regular configuration each trough 7 b issubstantially an inverse of each ridge 7 a.) The term “regular” is thusmeant to indicate that the corrugation (or flute) pattern comprisestroughs and ridges with each pair (comprising an adjacent trough andridge) repeating, without substantial modification in size and shape ofthe corrugations along at least 70% of the length of the flutes. Theterm “substantial” in this context, refers to a modification resultingfrom a change in the process or form used to create the corrugated orfluted sheet, as opposed to minor variations from the fact that themedia sheet 3 is flexible. With respect to the characterization of arepeating pattern, it is not meant that in any given filterconstruction, an equal number of ridges and troughs is necessarilypresent. The media 1 could be terminated, for example, between a paircomprising a ridge and a trough, or partially along a pair comprising aridge and a trough. (For example, in FIG. 1 the media 1 depicted infragmentary has eight complete ridges 7 a and seven complete troughs 7b.) Also, the opposite flute ends (ends of the troughs and ridges) mayvary from one another. Such variations in ends are disregarded in thesedefinitions, unless specifically stated. That is, variations in the endsof flutes are intended to be covered by the above definitions.

In the context of the characterization of a “curved” wave pattern ofcorrugations, the term “curved” is meant to refer to a corrugationpattern that is not the result of a folded or creased shape provided tothe media, but rather the apex 7 a of each ridge and the bottom 7 b ofeach trough is formed along a radiused curve. A typical radius for suchz-filter media would be at least 0.25 mm and typically would be not morethan 3 mm.

An additional characteristic of the particular regular, curved, wavepattern depicted in FIG. 1, for the corrugated sheet 3, is that atapproximately a midpoint 30 between each trough and each adjacent ridge,along most of the length of the flutes 7, is located a transition regionwhere the curvature inverts. For example, viewing back side or face 3 a,FIG. 1, trough 7 b is a concave region, and ridge 7 a is a convexregion. Of course when viewed toward front side or face 3 b, trough 7 bof side 3 a forms a ridge; and, ridge 7 a of face 3 a, forms a trough.(In some instances, region 30 can be a straight segment, instead of apoint, with curvature inverting at ends of the segment 30.)

A characteristic of the particular regular, wave pattern fluted (in thisinstance corrugated) sheet 3 shown in FIG. 1, is that the individualcorrugations are generally straight. By “straight” in this context, itis meant that through at least 70%, typically at least 80% of the lengthbetween edges 8 and 9, the ridges 7 a and troughs 7 b do not changesubstantially in cross-section. The term “straight” in reference tocorrugation pattern shown in FIG. 1, in part distinguishes the patternfrom the tapered flutes of corrugated media described in FIG. 1 of WO97/40918 and PCT Publication WO 03/47722, published Jun. 12, 2003,incorporated herein by reference. The tapered flutes of FIG. 1 of WO97/40918, for example, would be a curved wave pattern, but not a“regular” pattern, or a pattern of straight flutes, as the terms areused herein.

Referring to the present FIG. 1 and as referenced above, the media 1 hasfirst and second opposite edges 8 and 9. When the media 1 is formed intoa media pack, in general edge 9 will form an inlet end for the mediapack and edge 8 an outlet end, although an opposite orientation ispossible.

Adjacent edge 8 is provided a sealant bead 10, sealing the corrugatedsheet 3 and the facing sheet 4 together. Bead 10 will sometimes bereferred to as a “single facer” bead, since it is a bead between thecorrugated sheet 3 and facing sheet 4, which forms the single facer ormedia strip 1. Sealant bead 10 seals closed individual flutes 11adjacent edge 8, to passage of air therefrom.

Adjacent edge 9, is provided seal bead 14. Seal bead 14 generally closesflutes 15 to passage of unfiltered fluid therein, adjacent edge 9. Bead14 would typically be applied as strips of the media 1 are secured toone another during stacking. Thus bead 14 will form a seal between aback side 17 of facing sheet 4, and side 18 of the next adjacentcorrugated sheet 3. When the media 1 is cut in strips and stacked,instead of coiled, bead 14 is referenced as a “stacking bead.” (Whenbead 14 is used in a coiled arrangement formed from media 1, notdepicted herein, it is referenced as a “winding bead.”)

Referring to FIG. 1, once the media 1 is incorporated into a media pack,for example by stacking, it can be operated as follows. First, air inthe direction of arrows 12, would enter open flutes 11 adjacent end 9.Due to the closure at end 8, by bead 10, the air would pass through themedia, for example as shown by arrows 13. It could then exit the mediapack, by passage through open ends 15 a of the flutes 15, adjacent end 8of the media pack. Of course operation could be conducted with air flowin the opposite direction.

For the particular arrangement shown herein in FIG. 1, the parallelcorrugations 7 a, 7 b are generally straight completely across themedia, from edge 8 to edge 9. Straight flutes or corrugations can bedeformed or folded at selected locations, especially at ends.Modifications at flute ends for closure are generally disregarded in theabove definitions of “regular,” “curved” and “wave pattern.”

Z-filter constructions which do not utilize straight, regular curvedwave pattern corrugation shapes are known. For example in Yamada et al.U.S. Pat. No. 5,562,825 corrugation patterns which utilize somewhatsemicircular (in cross section) inlet flutes adjacent narrow V-shaped(with curved sides) exit flutes are shown (see FIGS. 1 and 3, of U.S.Pat. No. 5,562,825). In Matsumoto, et al. U.S. Pat. No. 5,049,326circular (in cross-section) or tubular flutes defined by one sheethaving half tubes attached to another sheet having half tubes, with flatregions between the resulting parallel, straight, flutes are shown, seeFIG. 2 of Matsumoto '326. In Ishii, et al. U.S. Pat. No. 4,925,561(FIG. 1) flutes folded to have a rectangular cross section are shown, inwhich the flutes taper along their lengths. In WO 97/40918 (FIG. 1),flutes or parallel corrugations which have a curved, wave patterns (fromadjacent curved convex and concave troughs) but which taper along theirlengths (and thus are not straight) are shown. Also, in WO 97/40918flutes which have curved wave patterns, but with different sized ridgesand troughs, are shown.

In general, the filter media is a relatively flexible material,typically a non-woven fibrous material (of cellulose fibers, syntheticfibers or both) often including a resin therein, sometimes treated withadditional materials. Thus, it can be conformed or configured into thevarious corrugated patterns, without unacceptable media damage. Also, itcan be readily coiled or otherwise configured for use, again withoutunacceptable media damage. Of course, it must be of a nature such thatit will maintain the required corrugated configuration, during use.

In the corrugation process, an inelastic deformation is caused to themedia. This prevents the media from returning to its original shape.However, once the tension is released the flute or corrugations willtend to spring back, recovering only a portion of the stretch andbending that has occurred. The facing media sheet is sometimes tacked tothe fluted media sheet, to inhibit this spring back in the corrugatedsheet. Such tacking is shown at 20.

Also, typically, the media contains a resin. During the corrugationprocess, the media can be heated to above the glass transition point ofthe resin. When the resin then cools, it will help to maintain thefluted shapes.

The media of the corrugated sheet 3 facing sheet 4 or both, can beprovided with a fine fiber material on one or both sides thereof, forexample in accord with U.S. Pat. No. 6,673,136, incorporated herein byreference. In some instances, when such fine fiber material is used, itmay be desirable to provide the fine fiber on the upstream side of thematerial and inside the flutes. When this occurs, air flow, duringfiltering, will typically be into the edge comprising stacking bead.

An issue with respect to z-filter constructions relates to closing ofthe individual flute ends. Although alternatives are possible, typicallya sealant or adhesive is provided, to accomplish the closure. As isapparent from the discussion above, in typical z-filter media,especially that which uses straight flutes as opposed to tapered flutesand sealant for flute seals, large sealant surface areas (and volume) atboth the upstream end and the downstream end are needed. High qualityseals at these locations are critical to proper operation of the mediastructure that results. The high sealant volume and area, creates issueswith respect to this.

Attention is now directed to FIG. 2, in which a z-filter mediaconstruction 40 utilizing a regular, curved, wave pattern corrugatedsheet 43, and a non-corrugated flat sheet 44, i.e., a single facer stripis schematically depicted. The distance D1, between points 50 and 51,defines the extension of flat media 44 in region 52 underneath a givencorrugated flute 53. The length D2 of the arcuate media for thecorrugated flute 53, over the same distance D1 is of course larger thanD1, due to the shape of the corrugated flute 53. For a typical regularshaped media used in fluted filter applications, the linear length D2 ofthe media 53 between points 50 and 51 will often be at least 1.2 timesD1. Typically, D2 would be within a range of 1.2-2.0 times D1,inclusive. One particularly convenient arrangement for air filters has aconfiguration in which D2 is about 1.25-1.35×D1. Such media has, forexample, been used commercially in Donaldson Powercore™ Z-filterarrangements. Another potentially convenient size would be one in whichD2 is about 1.4-1.6 times D1. Herein the ratio D2/D1 will sometimes becharacterized as the flute/flat ratio or media draw for the corrugatedmedia.

In the corrugated cardboard industry, various standard flutes have beendefined. For example the standard E flute, standard X flute, standard Bflute, standard C flute and standard A flute. FIG. 3, attached, incombination with Table A below provides definitions of these flutes.

Donaldson Company, Inc., (DCI) the assignee of the present disclosure,has used variations of the standard A and standard B flutes, in avariety of z-filter arrangements. These flutes are also defined in TableA and FIG. 3.

TABLE A (Flute definitions for FIG. 3) DCI A Flute: Flute/flat = 1.52:1;The Radii (R) are as follows: R1000 = .0675 inch (1.715 mm); R1001 =.0581 inch (1.476 mm); R1002 = .0575 inch (1.461 mm); R1003 = .0681 inch(1.730 mm); DCI B Flute: Flute/flat = 1.32:1; The Radii (R) are asfollows: R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm);R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm); Std. EFlute: Flute/flat = 1.24:1; The Radii (R) are as follows: R1008 = .0200inch (.508 mm); R1009 = .0300 inch (.762 mm); R1010 = .0100 inch (.254mm); R1011 = .0400 inch (1.016 mm); Std. X Flute: Flute/flat = 1.29:1;The Radii (R) are as follows: R1012 = .0250 inch (.635 mm); R1013 =.0150 inch (.381 mm); Std. B Flute: Flute/flat = 1.29:1; The Radii (R)are as follows: R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874mm); R1016 = .0310 inch (.7874 mm); Std. C Flute: Flute/flat = 1.46:1;The Radii (R) are as follows: R1017 = .0720 inch (1.829 mm); R1018 =.0620 inch (1.575 mm); Std. A Flute: Flute/flat = 1.53:1; The Radii (R)are as follows: R1019 = .0720 inch (1.829 mm); R1020 = .0620 inch (1.575mm).

Of course other, standard, flutes definitions from the corrugated boxindustry are known.

In general, standard flute configurations from the corrugated boxindustry can be used to define corrugation shapes or approximatecorrugation shapes for corrugated media. Comparisons above between theDCI A flute and DCI B flute, and the corrugation industry standard A andstandard B flutes, indicate some convenient variations.

It is noted that alternative flute definitions such as thosecharacterized in U.S. Ser. No. 12/215,718, filed Jun. 26, 2008; and Ser.No. 12/012,785, filed Feb. 4, 2008 can be used, with air cleanerfeatures as characterized herein below. The complete disclosures of eachof U.S. Ser. No. 12/215,718 and Ser. No. 12/012,785 are incorporatedherein by reference.

II. Manufacture of Stacked Media Configurations Using Fluted Media,Generally

In FIG. 4, one example of a manufacturing process for making a mediastrip corresponding to strip 1, FIG. 1 is shown. In general, facingsheet 64 and the fluted (corrugated) sheet 66 having flutes 68 arebrought together to form a media web 69, with an adhesive bead locatedtherebetween at 70. The adhesive bead 70 will form a single facer bead14, FIG. 1.

The term “single facer bead” references a sealant bead positionedbetween layers of a single facer; i.e., between the fluted sheet andfacing sheet.

An optional darting process occurs at station 71 to form center dartedsection 72 located mid-web. The z-filter media or Z-media strip 74 canbe cut or slit at 75 along the bead 70 to create two pieces 76, 77 ofz-filter media 74, each of which has an edge with a strip of sealant(single facer bead) extending between the corrugating and facing sheet.Of course, if the optional darting process is used, the edge with astrip of sealant (single facer bead) would also have a set of flutesdarted at this location. The strips or pieces 76, 77 can then be cutacross, into single facer strips for stacking, as described below inconnection with FIG. 6.

Techniques for conducting a process as characterized with respect toFIG. 4 are described in PCT WO 04/007054, published Jan. 22, 2004incorporated herein by reference.

Still in reference to FIG. 4, before the z-filter media 74 is putthrough the darting station 71 the media 74 must be formed. In theschematic shown in FIG. 4, this is done by passing a flat sheet of media92 through a pair of corrugation rollers 94, 95. In the schematic shownin FIG. 4, the flat sheet of media 92 is unrolled from a roll 96, woundaround tension rollers 98, and then passed through a nip or bite 102between the corrugation rollers 94, 95.

The corrugation rollers 94, 95 have teeth 104 that will give the generaldesired shape of the corrugations after the flat sheet 92 passes throughthe nip 102. After passing through the nip 102, the flat sheet 92becomes corrugated and is referenced at 66 as the corrugated sheet. Thecorrugated (i.e., fluted) media sheet 66 is then secured to facing mediasheet 64. (The corrugation process may involve heating the media, insome instances.)

Still in reference to FIG. 4, the process also shows the facing sheet 64being routed to the darting process station 71. The facing sheet 64 isdepicted as being stored on a roll 106 and then directed to thecorrugated sheet 66 to form the Z-media 74. The corrugated sheet 66 andthe facing sheet 64 are secured together by adhesive or by other means(for example by sonic welding).

Referring to FIG. 4, an adhesive line 70 is shown used to securecorrugated sheet 66 and facing sheet 64 together, as the sealant bead.Alternatively, the sealant bead for forming the facing bead could beapplied as shown as 70 a. If the sealant is applied at 70 a, it may bedesirable to put a gap in the corrugation roller 95, and possibly inboth corrugation rollers 94, 95, to accommodate the bead 70 a.

The type of corrugation provided to the corrugated media is a matter ofchoice, and will be dictated by the corrugation or corrugation teeth ofthe corrugation rollers 94, 95. One typical type of flute pattern willbe a regular, typically curved, wave pattern corrugation, of straightflutes, as defined herein above. A typical regular curved wave patternused, would be one in which the distance D2, as defined above, in acorrugated pattern is at least 1.2 times the distance D1 as definedabove. In one typical application, typically D2=1.25-1.35×D1; in anotherD2=1.4-1.6×D1. In some instances the techniques may be applied withcurved wave patterns that are not “regular,” including, for example,ones that do not use straight flutes.

As described, the process shown in FIG. 4 can be used to create thecenter darted section 72. FIG. 5 shows, in cross-section, one of theflutes 68 after darting and slitting.

A fold arrangement 118 can be seen to form a darted flute 120 with fourcreases 121 a, 121 b, 121 c, 121 d. The fold arrangement 118 includes aflat first layer or portion 122 that is secured to the facing sheet 64.A second layer or portion 124 is shown pressed against the first layeror portion 122. The second layer or portion 124 is preferably formedfrom folding opposite outer ends 126, 127 of the first layer or portion122.

Still referring to FIG. 5, two of the folds or creases 121 a, 121 b willgenerally be referred to herein as “upper, inwardly directed” folds orcreases. The term “upper” in this context is meant to indicate that thecreases lie on an upper portion of the entire fold 120, when the fold120 is viewed in the orientation of FIG. 5. The term “inwardly directed”is meant to refer to the fact that the fold line or crease line of eachcrease 121 a, 121 b, is directed toward the other.

In FIG. 5, creases 121 c, 121 d, will generally be referred to herein as“lower, outwardly directed” creases. The term “lower” in this contextrefers to the fact that the creases 121 c, 121 d are not located on thetop as are creases 121 a, 121 b, in the orientation of FIG. 5. The term“outwardly directed” is meant to indicate that the fold lines of thecreases 121 c, 121 d are directed away from one another.

The terms “upper” and “lower” as used in this context are meantspecifically to refer to the fold 120, when viewed from the orientationof FIG. 5. That is, they are not meant to be otherwise indicative ofdirection when the fold 120 is oriented in an actual product for use.

Based upon these characterizations and review of FIG. 5, it can be seenthat a preferred regular fold arrangement 118 according to FIG. 5 inthis disclosure is one which includes at least two “upper, inwardlydirected, creases.” These inwardly directed creases are unique and helpprovide an overall arrangement in which the folding does not cause asignificant encroachment on adjacent flutes.

A third layer or portion 128 can also be seen pressed against the secondlayer or portion 124. The third layer or portion 128 is formed byfolding from opposite inner ends 130, 131 of the third layer 128.

Another way of viewing the fold arrangement 118 is in reference to thegeometry of alternating ridges and troughs of the corrugated sheet 66.The first layer or portion 122 is formed from an inverted ridge. Thesecond layer or portion 124 corresponds to a double peak (afterinverting the ridge) that is folded toward, and in preferredarrangements, folded against the inverted ridge.

Techniques for providing the optional dart described in connection withFIG. 5, in a preferred manner, are described in PCT WO 04/007054,incorporated herein by reference. Other techniques for media managementare described in PCT application U.S. 04/07927, filed Mar. 17, 2004,incorporated herein by reference.

Techniques described herein are well adapted for use of media packs thatresult from arrangements that, instead of being formed by coiling, areformed from a plurality of strips of single facer.

Opposite flow ends or flow faces of the media pack can be provided witha variety of different definitions. In many arrangements, the ends aregenerally flat and perpendicular to one another.

The flute seals (single facer bead, winding bead or stacking bead) canbe formed from a variety of materials. In various ones of the cited andincorporated references, hot melt or polyurethane seals are described aspossible for various applications. These are useable for applicationsdescribed herein.

In FIG. 6, schematically there is shown a step of forming a stackedz-filter media pack from strips of z-filter media, each strip being afluted sheet secured to a facing sheet. Referring to FIG. 6, singlefacer strip 200 is being shown added to a stack 201 of strips 202analogous to strip 200. Strip 200 can be cut from either of strips 76,77, FIG. 4. At 205, FIG. 6, application of a stacking bead 206 is shown,between each layer corresponding to a strip 200, 202 at an opposite edgefrom the single facer bead or seal. (Stacking can also be done with eachlayer being added to the bottom of the stack, as opposed to the top.)

Referring to FIG. 6, each strip 200, 202 has front and rear edges 207,208 and opposite side edges 209 a, 209 b. Inlet and outlet flutes of thecorrugated sheet/facing sheet combination comprising each strip 200, 202generally extend between the front and rear edges 207, 208, and parallelto side edges 209 a, 209 b.

Still referring to FIG. 6, in the media pack 201 being formed, oppositeflow faces are indicated at 210, 211. The selection of which one offaces 210, 211 is the inlet end face and which is the outlet end face,during filtering, is a matter of choice. In some instances the stackingbead 206 is positioned adjacent the upstream or inlet face 211; inothers the opposite is true. The flow faces 210, 211, extend betweenopposite side faces 220, 221.

The stacked media pack 201 shown being formed in FIG. 6, is sometimesreferred to herein as a “blocked” stacked media pack. The term “blocked”in this context, is an indication that the arrangement is formed to arectangular block in which all faces are 90° relative to all adjoiningwall faces. Alternate configurations are possible, as discussed below inconnection with certain of the remaining figures. For example, in someinstances the stack can be created with each strip 200 being slightlyoffset from alignment with an adjacent strip, to create a parallelogramor slanted block shape, with the inlet face and outlet face parallel toone another, but not perpendicular to upper and bottom surfaces.

In some instances, the media pack will be referenced as having aparallelogram shape in any cross-section, meaning that any two oppositeside faces extend generally parallel to one another.

It is noted that a blocked, stacked arrangement corresponding to FIG. 6is described in the prior art of U.S. Pat. No. 5,820,646, incorporatedherein by reference. It is also noted that stacked arrangements aredescribed in U.S. Pat. Nos. 5,772,883; 5,792,247; U.S. Provisional60/457,255 filed Mar. 25, 2003; and U.S. Ser. No. 10/731,564 filed Dec.8, 2003. All four of these latter references are incorporated herein byreference. It is noted that a stacked arrangement shown in U.S. Ser. No.10/731,504, is a slanted stacked arrangement.

III. Air Cleaner Assembly and Components, Useable with a Media Pack ForExample in General Accord with FIG. 6 A. General Air Cleaner Features

Herein, example air cleaner assemblies and components are described, forimplementing a media pack in general accord with FIG. 6.

Referring first to FIG. 7, at 300 an air cleaner assembly is depicted.The air cleaner assembly 300 includes a housing 301 and an internallyreceived, removable and replaceable, primary filter cartridge 302, notviewable in FIG. 7, see FIG. 8 discussed below.

It is noted that the air cleaner assembly 300 may include an optionalsecondary or safety filter cartridge positioned therein as well, asdiscussed below.

Referring still to FIG. 7, housing 301 generally includes a housing body305 and an openable access cover 306. The access cover 306 is openablewith respect to housing body 305, to allow service access to an interior301 i, of housing 301, and filter cartridge 302 positioned therein.

Still referring to FIG. 7, housing 305 includes an air flow inletarrangement 310 and an air flow outlet arrangement 311.

In general terms, air to be filtered is directed into air cleanerassembly 300, in the direction indicated by inlet arrow 312. Within theair cleaner assembly 301, air is passed through a filter cartridge 302,with filtering. Filtered air is then directed into air flow outletarrangement 311, and for the particular air cleaner assembly 300depicted, the filtered air exits the air cleaner assembly 300 in thegeneral direction of arrow 313.

Thus, for the particular example assembly 300 depicted, the housing 301is configured so that air flow, when viewed from the side, moves in agenerally u-shaped orientation; i.e. it enters the housing 301 by beingdirected downwardly; it is directed laterally as it moves through aninteriorly received cartridge 302; and, upon exiting the housing 301filtered air is directed in the direction of arrow 313 in a directiongenerally opposite to that from which it entered housing 301.

It is noted that the inlet arrangement 310 can be provided with aprecleaner arrangement therein, for example in the form of a pluralityof separator tubes, for example of the type as referenced generally inU.S. Ser. No. 61/130,790 filed Jun. 2, 2008 and/or as described morespecifically in WO 03/084641 published Oct. 16, 2003, U.S. Pat. No.4,242,115 or U.S. Pat. No. 4,746,340, each of which is incorporatedherein by reference. An array of such tube arrangements can optionallybe positioned within an interior 310 i of inlet 310. Further, foroperation of such an arrangement, scavenge exit 310 e can be provided inthe inlet arrangement 310, to be attached to a scavenge duct system,i.e. vacuum draw. It is noted that herein housing 301 is depicted in theabsence of such a precleaner, but configured for such a precleaner ifoptionally used.

Referring to FIG. 7, it is noted that housing 301 includes mountingbrackets 315 thereon, for mounting air cleaner housing 301 on equipmentwith which the housing 300 is to be used, for example a tractor. It isnoted that brackets 315 are mounted on the housing body 305, to allowfor selected movement of the access cover 306 during a typical servicingoperation.

Still referring to FIG. 7, it is noted that an inlet baffle or duct maybe provided in engagement with inlet 310, to direct intake air to theair cleaner assembly 300. Further, outlet duct work may be secured tooutlet 311 to direct filtered air to appropriate downstream componentry,for example ultimately to a combustion air intake for a engine of avehicle or other equipment on which the air cleaner assembly 300 isused.

Attention is now directed to FIG. 8, a view analogous to FIG. 7, butdepicted with access cover 306 configured in an open position, ratherthan in the closed position of FIG. 7. In particular, access cover 306has been pivoted around pivot 320, i.e. downward, to open end 321 ofbody 305, for service access to cartridge 302.

Still referring to FIG. 8, arrow 314 is positioned to indicate thegeneral direction of flow of air to be filtered, into cartridge 302.

It is noted that pivot 320 can be a hinge capable of disconnection, or,alternatively, a hinge incapable of disconnection, as desired.

Generally, end 322 of access cover 306 provides for an upper closurelatch. In the example air cleaner assembly 300 depicted, end 322includes a tube section 323, which mates with a tube section 324 on thehousing body 305. A release rod 325 can be projected through the tubesections 323, 324, to secure the housing 301 closed; which rod, whenremoved, allows access cover 306 to pivot around pivot 320 and thusopen. The release rod can be provided with a handle on one end, and akey or similar construction removably positioned on an opposite end, ifdesired. A variety of alternate closure arrangements can be used.

Still referring to FIG. 8, it is noted that the access cover 306 can beraised or lowered once the air cleaner assembly 300 is mounted in placeby brackets 315, since the brackets 315 are positioned on the housingbody 305, which does not need to move as the access cover 306 is openedand closed. In FIG. 9, a schematic top plan view of the assembly 300 isdepicted. Here rod 325, for operation to close access cover 306, isviewable projecting through tube sections 323 and 324.

In FIG. 9, a cross-section line 10-10, is provided to identify thecross-sections of FIGS. 10 and 16 as discussed further below.

In FIG. 14, an end elevational view directed toward access cover 306 isprovided. Again, control rod 325 is viewable, for access cover 306. InFIG. 15, a bottom plan view of air cleaner assembly 300 is provided. InFIG. 13, and end view toward an opposite end from FIG. 14, i.e. towardoutlet 311 is provided.

Referring to FIGS. 9 and 13, it is noted that in general outlet 311includes an elongate and generally circular tube section 328 extendingvertically along an end of housing body 305. Alternative shapes anddirection of flow are possible.

Attention is now directed to FIG. 10, a schematic cross-sectional viewdefined generally by line 10-10, FIG. 9, but depicting the air cleanerassembly 300 with the access cover 306 open, i.e. in a loweredorientation. In general terms, the access cover 306 can be characterizedas having an open orientation, FIG. 10, and a closed orientation, FIG.7. Further it can be characterized as having a raised orientation, FIG.7, i.e. corresponding to the closed orientation; and, a loweredorientation, FIG. 10, i.e. corresponding to the open orientation.

Referring to FIG. 10, interior 301 i of housing 301 can be viewed ashaving, operably (and removably) positioned therein, cartridge 302.Cartridge 302 comprises a media pack 330 having an inlet flow face 331,and opposite outlet flow face 332. In general terms, the media pack 330comprises flutes extending in a direction between opposite inlet andoutlet flow faces 331, 332, and sealed appropriately to cause airentering face 331 to pass through media, before exiting face 332.Typically, the media pack 330 will comprise strips of media, the stripsgenerally comprising single facer strips of fluted media secured tofacing media, as previously described in connection with FIGS. 1-6, forexample. The particular example media pack 330 depicted comprises ablocked configuration of stacked strips. Referring to FIG. 10, thestrips generally extend between ends 334, 335, with the flutes extendinggenerally in a direction between flow faces 331, 332.

The cartridge 302 also generally includes, secured to the media pack330, a housing seal arrangement 340. The housing seal arrangement 340 isdiscussed in greater detail below, and provides for a sealingarrangement between the cartridge 302 and the housing 301, whencartridge 302 is operably installed within the housing 301. The housingseal arrangement 340, then, generally helps to provide that unfilteredair entering the air cleaner assembly 300 in the direction of arrow 312,FIG. 10, does not reach outlet arrangement 311 without passing throughmedia of the media pack 330, with filtering.

Still referring to FIG. 10, it is important to inhibit cartridge 302from backing out of its sealed orientation, FIG. 10, once installed. Toprovide for this, the access cover 306 is provided, on an interior 306 ithereof, with lock arrangement 344, in the example shown comprising apair of oppositely positioned projections 344 x, 344 y one of which (344x) is positioned on side 306 a of access cover 306, as viewable in FIG.10. It is noted that on opposite side 306 b, FIG. 18, is provided ananalogous projection 344 y. Projection arrangement 344 is configured tooverlap and block cartridge 302 from moving in a direction oppositearrow 314, FIG. 10, when access cover 306 is in the closed orientationof FIG. 7.

Referring to FIG. 10, it is noted as the air enters inlet 311 in thegeneral direction of arrow 312, it will need to make a turn in order toenter the cartridge 302 in the general direction of arrow 314. Tofacilitate turning of the air, while providing good flow distributionacross inlet face 331, end face or wall 306 c of access cover 306,overlapping cartridge face 331, is configured to slant inwardly in ageneral direction from upper end section 322 x toward lower end 322 y.The slant is generally shown in FIG. 7 at angle X. The angle X of slantregion 306 c, (which is a portion extending between the sides 306 a, 306b) is, typically, relative to the face 331 of media pack 302, an acuteangle of at least 15°, and not more than 40°, usually within the rangeof 20°-35°.

Attention is now directed to FIG. 11, a top, outlet end, perspectiveview of air cleaner assembly 300. It can be seen that an interior 310 iof inlet arrangement 311 is shown devoid of a precleaner arrangement,comprising a plurality of separator tubes. However, an array ofseparator tubes, for example, as previously referenced, can bepositioned in interior 310 i, if desired.

In FIG. 12, an access cover end perspective view of air cleaner assembly300 is provided.

It is noted that the air cleaner assembly 300 can be configured to bemanufactured from sheet metal components, as generally indicated in theexample depictions of FIGS. 7-12. It is also noted that the housing 301and access cover 306 can alternatively be configured as molded plasticcomponents. When the housing comprises molded plastic components, someshape variation may be desirable.

It is noted that many of the features characterized herein, with respectto the seal arrangement on filter cartridge 302, discussed below, weredeveloped to accommodate variability in seal surfaces, when relativelylong seals surfaces are needed, especially in a molded plastic housing.This is discussed further below. An issue for observation, then, is thatthe metal housing depicted in FIG. 7, is used as an example to indicategeneral features. It is anticipated that in a commercial product, thehousing will be made from molded plastic components.

In FIG. 16, a cross-sectional view taken along line 10-10, FIG. 9, butdepicted with access cover 306 closed is shown. Here an interior surface306 e can be seen, slanting inwardly at the identified angle X, inextension from end 322 y and end 322 x. Cartridge 302 is viewable,secured in place by projection arrangement 344.

In FIG. 17, a side elevational view of housing 301 is provided, withaccess cover 306 open, and with cartridge 302, FIGS. 10 and 16 removed.

Attention is now directed to FIG. 18. FIG. 18 is a view of housing 301with cartridge 302, FIG. 16, removed. The view of FIG. 18 is with accesscover 306 lowered or open relative to housing body 305. Further, theview is directed toward interior 305 i of housing body 305, and interior306 i access cover 306.

Referring first to the access cover 306, the opposite sides 306 a, 306 band end wall 306 c can be viewed. On the opposite sides 306 a, 306 b,projection members 344 x 344 y, respectively, of lock arrangement 344are viewable. It can be seen that these projections 344 x 344 y willoverlap an end of an installed cartridge (302 of FIG. 16), when acartridge 302 is installed, as cover 306 is moved to a closed position.This will prevent the cartridge 302 from moving out of the sealedorientation, within housing body 305 i.

Still referring to FIG. 18, at 320 the pivot connection 320 between theaccess cover 306 and the housing body 305 is viewable as a hinge 320 h.

Referring to FIG. 18, it is noted that rod 325 is shown positioneddirected through tube section 324. Normally, to open housing body 301,rod 325 would be withdrawn through tube sections 323, 324. In thisinstance, the rod 325 has been repositioned in tube section 324 after aninitial withdrawal to allow for opening. For FIG. 18, end ring 325 x, onone end of rod 325 is viewable, for easy grasping. Key aperture 325 y isviewable at an opposite end, for receipt of a key therethrough, to lockrod 325 in place.

In FIG. 18, as indicated above, portions of interior 305 i of housingsection 305 are viewable. For example, outlet aperture 348, allowing airflow between interior 305 i and outlet arrangement 311 is viewable inend wall 349 of housing body 305, opposite edge 321 and, when closed,opposite access cover inner wall 306 c. For the particular exampledepicted, the outlet aperture 348 has an oval shape, with oppositecurved ends 348 a, 348 b, and sides 348 c, 348 d extending therebetween.For the example depicted, opposite sides 348 c 348 d each have a centralstraight section.

The particular housing body 305 depicted, includes a seal groove 350 inend wall 349, defining a perimeter groove around outlet aperture 348.The particular seal groove 350 depicted is generally rectangular inperimeter definition, although alternative shapes are possible. Detailregarding the seal groove 350 is provided further below. In general, theseal groove 350 is configured to receive, projecting therein, a housingseal member on cartridge 302, with the housing seal member on cartridge302 sealed within the groove 350, to provide a housing seal between acartridge 302 and the housing body 305.

B. General Features of the Cartridge 302

Before seal engagement between the cartridge 302 and the housing 301,(in particular by engagement of a housing seal arrangement 340 of thecartridge 302 with sealing groove 350 and housing body 305), aredescribed in detail, general features of the cartridge 302 arediscussed.

Attention is first directed to FIGS. 19 and 20, in which the cartridge302 is viewed in perspective view.

Attention is first directed to FIG. 19. FIG. 19 is an inlet flow faceperspective view of the cartridge 302. As previously characterized, thecartridge 302 includes a media pack 330 defining an inlet flow face 331and opposite outlet flow face 332. Also, as previously characterized,the media pack 340 generally comprises flutes extending in the directionbetween the flow faces 331, 332. The particular media pack 330,comprises strips of fluted media secured to facing media (generallycharacterized herein as single facer strips), stacked with each singlefacer strip in extension between ends 334 and 335. It is noted that inthe cartridge depictions herein, including FIG. 19, the media pack 330is depicted schematically, and specific details of media sheet layers(for example alternating fluted and spacing sheet layers) are not shown,nor are specific media pack flute seals specifically depicted.

Still referring to FIG. 19, the air filter cartridge 302 can be viewedas having: first and second, opposite, flow faces 331, 332; first andsecond, opposite, ends 352, 353; (sometimes called side ends) and, firstand second, opposite, sides 354, 355. The ends 352, 353 generallycorrespond to, and overlap, ends 334, 335, respectively, of media pack330. Sides 354, 355 are opposite one another, and generally extendbetween ends 352, 353, along opposite sides 330 a, 330 b, respectively,of media pack 330. The inlet and outlet flow faces 331, 332, for themedia pack 330 and the cartridge 302 are the same.

Still referring to FIG. 19, ends 352, 353 comprise end covers or pieces352 a, 353 a respectively. End pieces 352 a, 353 a are typicallymolded-in-place, providing for a sealing therein of ends 334, 335 ofmedia pack 331. Typically end pieces 352 a, 353 a will comprisemolded-in-place foamed polyurethane, as described below.

Still referring to FIG. 19, extending along the sides 354, 355, ofcartridge 302, adjacent inlet face 331, are provided opposite,outwardly, laterally, extending flanges 358, 359; flange 358 extendalong side 354 adjacent face 331; and, flange 359 extending along side355 adjacent face 331. The flanges 358, 359 extend generally oppositeone another, in extension away from media pack 330. Flanges 358, 359provide for several effects. First, they facilitate removal of thecartridge 302 from the housing 301, by allowing the service provider tograb the opposite flanges 358, 359, by positioning fingers aroundopposite sides of the flanges 358, 359 from those viewable in FIG. 19.Secondly, flanges 358, 359 are positioned to be overlapped by theprojection arrangement 344, to help secure the cartridge 302 withinhousing body 305, once installed. Further, flanges 358, 359 along with aportion of a shell component described below, define an outward flangegap providing for positioning of a sealant, as discussed below, duringcartridge manufacture.

Still referring to FIG. 19, sides 354, 355 including flanges 358, 359,are typically portions of a shell 360, discussed below, manufactured asa preform component of the cartridge 302. By the terms “preform,”“preform component” and variants thereof herein, in this context, it ismeant that the shell 360 is manufactured before the cartridge 302, andis assembled with other componentry to make the cartridge 302. Incontrast, the example end pieces 352 a, 353 a, depicted, whenmolded-in-place, are not preforms, but rather are formed as thecartridge 302 is being formed. It is noted that the molded-in-place endpieces 352 a, 353 a, secure the shell 360 in position in the cartridge302, as discussed below.

Attention is now directed to FIG. 20. FIG. 20 is an outlet andperspective view of cartridge 302; i.e., the view is taken generallytoward end 352 and outlet flow face 332. Referring to FIG. 20, housingseal arrangement 340 is viewable. The particular housing sealarrangement 340 depicted, comprises a (peripherally) rectangular sealmember 365, having four straight sections 365 x with rounded corners 365y. The seal member 365 is described further below, in connection withother figures. Typically, each straight section 365 x of the housingseal arrangement 365 is at least 6 inches (152 mm) long, and, often, atleast the longer sections are substantially longer (10 inches, i.e. 254mm, or longer).

Still referring to FIG. 20, extending across outlet face 332, cartridge302 includes a support grid 370. Support grid 370 generally comprises alattice of strips 371, which, among other things, provides fordownstream support to media pack 331, along outlet face 332. Typicallythe support grid 370 will comprise an integral portion of shell 360, andwill provide some strength to the shell 360, along an end thereof.

Attention is now directed to FIG. 21. FIG. 21 is an outlet end plan viewof cartridge 302. The view is generally taken towards support grid 370.Opposite flanges 358, 359 are viewable. The rectangular shape (fourstraight sides 365 x with rounded corners 365 y) to seal member 365 canbe viewed.

FIG. 22 is a side elevational view of cartridge 302, taken generallytowards side 354. Here a side portion of shell 360 is viewable havingstrengthening ribs 373 thereon, extending between opposite faces 331,332 of enclosed media pack 330, not viewable in FIG. 22.

Still referring to FIG. 22, housing seal arrangement 340 is viewable inthe side elevational view. The housing seal arrangement 340 is generallypositioned projecting (axially) outwardly from adjacent flow face 332 ofmedia pack 330, in a direction away from flow face 331.

Attention is now directed to FIG. 23. FIG. 23 is generally across-sectional view taken along line 23-23, of FIG. 21. Referring toFIG. 23, media pack 330 is shown in schematic cross-sectional view,extending between inlet flow face 331 and outlet flow face 332. Oppositeends 334, 335 are viewable embedded within end pieces 352 a, 353 arespectively.

Still referring to FIG. 23, it is noted that the cross-section shows aseal projection arrangement or portion of shell 360 extending away fromend face 332, and embedded within seal material of housing sealarrangement 340. That projection portion is indicated generally at 375.In general terms, shell projection arrangement 375 is positioned tosupport seal material 341 of housing seal arrangement 340 thereon, inextension axially away from face 332. Typically the shell sealprojection arrangement 375 (which supports housing seal arrangement 340)is configured to be somewhat flexible, with respect to forcesperpendicular thereto. This is discussed in greater detail below. Theparticular seal projection arrangement 375 depicted, in part, isconfigured to provide for this flexibility, by comprising a plurality ofspaced tabs 376. The individual tabs 376 provide for some flexibility ina direction perpendicular, i.e., orthogonal, to the direction ofextension of seal projection arrangement 375. For the particularcross-section viewed in FIG. 23, this flexibility would be in directionsgenerally toward and away from the viewer. Advantages from this flexiblenature to projection arrangement 375 are discussed below.

In FIG. 24, an enlarged fragmentary view of a selected portion of FIG.23 is depicted; the portion shown in FIG. 24 depicting part ofprojection arrangement 375 embedded within a seal member 365 (i.e. sealmaterial 341) of housing seal arrangement 340. In particular, spacedtabs 376 are viewable in cross-section. For the example depicted, theindividual tabs 376 are spaced by gaps 377 which are typically at least1 mm wide, usually not more than 35 mm wide, and which are often withinthe range of 2 to 20 mm wide, inclusive, (typically at least 5 mm)indicated at dimension AC. The individual tabs 376 are typically atleast 1 mm wide, usually not more than 35 mm wide, and often 2 to 20 mmwide, inclusive, typically at least 5 mm wide, as indicated at dimensionAD. The length of the individual tabs 376, generally indicated atdimension AA, usually not more than 30 mm long, and often is within therange of 2 to 20 mm, inclusive, often at least 5 mm and typically 5-15mm, inclusive. Alternatives are possible for any of the abovedimensions.

Herein in connection with figures, some example dimensions are providedto indicate an example system. Of course variations in the dimensionsare possible. In FIG. 24, example dimensions indicated, from examplecartridge 302, would be as follows: AA=2-15 mm; AB=2-10 mm; AC=2-20 mm;and, AD=2-20 mm.

There is no specific requirement that all tabs 376 have the same width,or that all gaps 377 have the same width. It is specifically noted thatat the ends of each of the four sides of the projection 375, opencorners, discussed below, are generally present. By the term “open” inthis context, it is meant that adjacent sides of the projection 375 donot join adjacent the tabs 376, at the corners. This increasesflexibility of each of the sides. Adjacent the corners, wide tabs,relative to the other tabs, may be present. Typically, the tabs adjacentthe open corners will be truncated to not curve into the corner; and, ingeneral, the various tabs 376 will not have lateral supports such asstruts or gussets thereon, inhibiting flexibility. Of course at the gaps377, seal flexibility also results from the fact that seal material 341fills the gaps, and is itself flexible.

Referring back to FIG. 23, the total cartridge length, between mediapack ends 334, 335, would typically be about 378 mm (300-450 mm,inclusive), for the example assembly depicted. Principles describedherein are particularly advantageous, for cartridges having a media packlength between opposite sides 334, 335, in the order of at least 300 mm,typically at least 350 mm, and often within the range 350 mm-450 mm,inclusive, although alternative sizes are possible. These lengths wouldalso approximate the total length of the cartridge 302, as the length ofthe cartridge 302 only differs from the length of the media pack 330, bypartial thickness of the side pieces 352 a, 353 a.

Attention is now directed to FIG. 25. FIG. 25 is a cross-sectional viewof cartridge 320 taken generally along line 24-24, FIG. 21. Here themedia pack 330 is again depicted in schematic cross section, extendingbetween opposite flow faces 331, 332. Opposite sides 354, 355 areviewable, with outer flares, flanges or projections 358, 359 thereon.

Referring to FIG. 25, shell 360 is viewed in cross section, havingopposite sides 354, 355. Housing seal arrangement 340 is viewable, againcomprising (shell) projection arrangement 375, projecting away from endface 332. Shell projection arrangement 375, for the example depicted,comprises a plurality of spaced tabs 376, separated by gaps 377. Thus,throughout its perimeter extension, projection arrangement 375 of shell360, (which projects outwardly away from outlet face 332), comprises aplurality of spaced tabs 376 defining a parallelogram perimeter shape,in this instance rectangular.

Thus, in a typical assembly, the projection arrangement 375 comprises arectangular perimeter, with four sides and four open corners; the sidescomprising a first pair of opposite (longer) sides; and, a first pair ofopposite (shorter) ends. Typically, the longer sides can becharacterized as having a length L₁, the shorter ends having a lengthL₂, with L₁ greater than L₂. Typically L₁ is at least 50 mm longer thanL₂, usually 80 mm or more.

Typically, shell projection arrangement 375, which operates as a supportmember 375 s for seal material 341 (and seal member 365) of housing sealarrangement 340, is positioned in at least partial axial overlapcartridge outlet flow face 332. By this, it is meant that the projectionarrangement 375, and the resulting seal arrangement 360, can be viewedas projecting outwardly from adjacent end face 332, and in at leastpartial axial overlap with the end face 332.

Attention is now directed to FIG. 26, an enlarged fragmentary view of anidentified portion of FIG. 25. Here, seal material 341 can be viewed, aswell as a portion of shell projection arrangement 375, including tabs376 spaced by caps 377.

By comparison of FIGS. 23, 24, 25, and 26, it will again be understoodshell projection arrangement 375 is generally rectangular, and has fouropen corners or corner gaps. That is, gaps between adjacent ones of tabs376 are positioned in each of the four corners. Alternatives arepossible, however the particular configuration depicted is desirable forreasons discussed below.

In FIG. 26, some example dimensions for an example application areprovided as follows: BA=2-10 mm; BB=2-20 mm; BC=2-20 mm; and BD=2-15 mm.Alternatives are of course possible.

Attention is now directed to FIG. 27, an end elevational view ofcartridge 302, directed generally toward end piece 352 a, of end 352. Anexample dimension, for a total height or depth of example cartridge 302is provided, as follows: CA=241 mm. In FIG. 27, the features viewableinclude housing seal arrangement 340, and end flanges 358, 359.

In FIG. 28, a side elevational view of cartridge 302 is provided,generally analogous to view 22 but inverted; the view taken beinggenerally directed towards side 354. Here, cross-section line 29-29,identifying for the cross sectional view of FIG. 29, is depicted.Referring to FIG. 29, the cross-sectional view of cartridge 302 isgenerally parallel to end piece 352 a. Here, cross-sections of oppositesides 344, 355 are viewable, including a cross-sectional view of flanges358, 359.

Attention is now directed to FIG. 31, an enlarged fragmentary view of aselected portion of FIG. 29. Here attention is directed to a regionadjacent flange 359. It is noted that between cartridge 302 and flange359 is provided a gap 390. The gap 390 generally extends along a longerside 330 b of media pack 330, between the media pack 330 and the flange359, in a region immediately adjacent inlet flow face 331. In general,gap 390 provides a receiving space for sealant applied along the side330 b of the media pack 330 in this region. An analogous gap 391, FIG.29 is positioned adjacent flange 358.

In general, when cartridge 302 is constructed, a pre-made media pack 330is positioned within shell 360. A strip of sealant is positioned withingaps 390, 391, to ensure seals between the media pack 330 and shell 360,along opposite sides 330 a, 330 b of the media pack 330 (the flanges358, 359 comprising portions of shell 360).

In FIG. 31, some example dimensions are provided as follows: EA=5 mm;and, EB=4.5 mm.

C. The Housing Seal Arrangement 340

In this section, interaction between the housing seal arrangement 340and the housing 301 is described. Attention is first directed to FIG.30, an enlarged fragmentary cross-sectional view depicting a portion ofthe cartridge 302 viewable in FIG. 29, inserted within a portion of sealgroove 350 of housing 301, FIG. 18.

Referring to FIG. 30, attention is first directed to portions of housing301 depicted in cross-section, in that figure. Groove 350 can be seen asdefined by an inner (side) wall 395 an opposite outer (side) wall 396and an end wall 397. Groove 350 will typically be at least 8mm and notmore than 25 mm, wide (usually 9-18 mm wide, inclusive); and, at leastabout 25 mm, deep, for typical applications according to the presentdisclosure. Typically, at least the inner wall 395, and often both theinner wall 395 and the outer wall 396, of groove 350, will be in axialoverlap with the outlet flow face 332 of the media pack 330, whenpositioned. By this, it is meant that typically the groove 350 isdirectly aligned over a portion of face 332, and is not axially alignedwith space peripherally around face 332.

As discussed in connection with FIG. 18 above, the groove 350 isgenerally sized and positioned to extend peripherally around outletaperture 348, typically spaced therefrom. Thus, seal groove 350 isoriented to provide a seal location which will isolate a clean airregion at outlet aperture 348, from an unfiltered air region withinhousing 301.

Referring to FIG. 30, attention is now directed to portions of cartridge302 depicted in cross-section. Here, a portion of shell 360 is viewable,in particular a portion of (shell) projection seal arrangement 375. Itcan be seen that mounted on shell projection portion 375 is providedseal member 365, comprising seal material 341. Seal member 365 includes:a peripherally (radially) outer portion 401; opposite radially inwardlyfacing or peripherally inner portion 402; and, an end tip 403. Ingeneral, peripherally outer portion 401 surrounds an outer face 375 x,of a portion of shell projection arrangement 375. Peripherally innerportion 402, is surrounded by an inner surface 375 i of a portion ofshell projection arrangement 375; and, end tip 403 extends over (and inthe view of FIG. 30 under) an end 375 e of a portion of shell projectionarrangement 375.

Typically, seal member 365 will be molded-in-place, often comprising afoamed polyurethane as described herein below.

For the particular example cartridge 302 depicted, the outer (radiallydirected) peripheral portion 401 has an end portion 401 x, whichengages, i.e. presses against, an end portion 375 z of projecting shellprojection arrangement 375 which is in overlap with media pack outletflow face 332, and which turns outwardly (radially) to engage side wall355; an analogous portion being adjacent opposite side 354.

Inner (radially directed) region 402 also rises and terminates. Howeverin the depiction shown in FIG. 30 it is depicted risen against one ofthe strips 371 of grid 370. On opposite sides of the strips 371, theseal material will typically rise further, but not preferablysufficiently high to engage outlet face 332 and block flow therefrom.

Typically, then, when formed, seal member 365 will be molded in a freerise process.

Still referring to FIG. 30, attention is directed to the cross-sectionalshape of housing seal member 365. In particular, outer peripheralsection 401 includes an outer surface 401 s, with a longitudinal centralrib 405 thereon. In general, rib 405 extends peripherally(longitudinally) completely around seal member 400, and is integraltherewith. Rib 405 generally projects radially outwardly from adjacentportions of outer peripheral member 401, at opposite sides of rib 405,by a distance of at least 0.4 mm and usually at least 0.6 mm, forexample an amount within the range of 0.6-2.3 mm, inclusive. Rib 405 isan interference rib, and is depicted drawn in overlap with wall 396, toshow an amount of interference (compression) when installed. For theparticular example depicted, rib 405 is continuous in extensionperipherally around housing seal arrangement 440, i.e. around outersurface 401, and thus operates as a seal rib, to provide sealingengagement with inner surface 396 s of outer side wall 396, of groove350.

Also, attention is directed toward inner (radially directed) peripheralregion 402 for seal member 365. For the particular example seal member365 depicted, inner peripheral portion 402 includes rib 406 thereon,projecting radially inwardly from adjacent portions, both above andbelow, rib 406, of seal member 400 a distance of at least 0.4 mm usuallyat least 0.6 mm, and analogously to rib 405. For the particular exampledepicted, rib 406 provides for a radial inward engagement with innerwall 395 of groove 350. For the example depicted, rib 405 is integralwith the remainder of seal member 365, and extends continuously(longitudinally) peripherally around inner peripheral region 402. Thus,for the particular example assembly depicted in FIG. 30, rib 405provides for sealing engagement with surface 395 s of inner wall 395 ofgroove 350. In FIG. 30, overlap between rib 402 and wall 395 is depictedto show an amount of interference (compression) when installed.

From the above, it will be understood that the example cartridge 302depicted, includes a housing seal arrangement 340 configured to projectinto a groove 350 in a housing 301, engaging, within interference fit,opposite inner and outer side walls, 395, 396 of the groove 350. Theparticular interference fit depicted for the example of FIG. 30, is asealing interaction. Thus, the particular housing seal arrangement 340depicted, forms both an inwardly directed radial seal and an outwardlydirected radial seal, completely therearound, with groove 350.

Still referring to FIG. 30, some example dimensions are provided asfollows: DA=10 mm; DB=16.6 mm; DC=5.7 mm; DD=5.7 mm; DE=3 mm; DF=3.1 mm;DG=6.4 mm; and, DH=0.8 mm.

In general, then, housing seal arrangement 340 is a radial sealarrangement, meaning that the seal forces are generally directedradially rather than axially. Herein, the term “axially” refers to adirection generally corresponding to air flow through the media pack330, i.e., in a direction between inlet flow face 331 and outlet flowface 332. The term “radially”, is generally meant to refer to forcesdirected generally orthogonal to the axial direction.

FIG. 32 is a plan view of cartridge 302, directed generally towardoutlet flow face 332 of media pack 330. Thus, FIG. 32 is analogous toFIG. 21. The width dimension of the cartridge 302, between the oppositeflanges 358, 359 is designated by dimension FA, for example, as follows:FA=258 mm.

FIG. 32A is a cross-sectional view taken along line 32A-32A, FIG. 32.

FIG. 33 is an enlarged fragmentary view of an identified portion of FIG.32A. Features are generally analogous to those described above withrespect to FIG. 30 are analogously referenced. Some dimensions areprovided as follows: GA=10-60 mm, inclusive; GB=7.5 mm; GC=0.25-5°,inclusive; GD=7.5 mm; and, GE=5 mm.

In FIG. 33, attention is directed to a portion of molded-in-place sidewall 352, depicted generally at 352 x. In particular flange 360 x isshown embedded in portion 352 x of molded-in-place side wall 352. Flange360 x of shell 360 would typically include apertures therein, for flowof material therethrough, while molding-in-place side wall 352, forsecure engagement. Analogous interaction will be provided along anopposite side of shell of 360 from that viewable in FIG. 33. Thesefeatures are discussed further below, when assembly of cartridge 302 isdiscussed.

D. Shell Member 360; Assembly of Cartridge 302.

Attention is now directed to FIGS. 34-44, in which shell 360 andfeatures of shell 360 are depicted. It is noted that typically shell 360be a molded plastic part, for example molded from recycled nylon oranother plastic, for example polypropylene, ABS or in some instances,hard urethane. It will be a preform, i.e., it will be formed in advanceof manufacture of the cartridge 302, and used as one of the componentsfor formation of the cartridge 302.

Referring first to FIG. 34, an outlet perspective view of shell 360 isdepicted. The opposite sides 354, 355, each respectively having aoutwardly directed, end flange 358, 359 are viewable. Strengthening ribs373 extending cross side 354 are viewable and side 355 would typicallyhave analogous ribs.

Projection arrangement 375 is viewable at outlet or outlet end 410,which also has support grid 370 extending thereacross. Projectionarrangement of 375 comprises a plurality of tabs 376 spaced by gaps 377.It is noted that the projection arrangement 375 generally defines arectangular shape; in the example depicted having four open corners 415,i.e., one of the gaps 377 is positioned in each corner 415. Shellprojection arrangement 375, then, has first and second opposite longsides 417, 418 first and second opposite short sides 419, 420; each ofsides 417, 418, 419, 420 being straight, in the example depicted.

In FIG. 35, an opposite perspective view to FIG. 34, of shell 360 isdepicted. At 411, ends of sides 354, 355, remote from outlet end 410 areshown. End 411 is sometimes characterized here as defining “an inlet” or“inlet end,” or “inlet face” to preform 360. The reason for thesecharacterizations, is that adjacent regions 411, will be positioned aninlet face 331 for a media pack 330 when the cartridge 302 is assembled;i.e. air will enter preform 360 adjacent regions 411, as it passesthrough the resulting cartridge 302.

FIG. 36 is a side elevational view of shell 360.

Shell 360 extends between first and second opposite, open, ends (or sideends) 430, 431.

The same features as identified with respect to FIGS. 34 and 35 areidentified with same reference numerals.

FIG. 37 is an enlarged fragmentary view of an identified portion of FIG.36. Here, some example tabs 376 are depicted, along with some identifieddimensions, as follows: HA=11 mm (typically); HB=10 mm (typically); andHC=10 mm (typically). Of course these dimensions may be varied, aspreviously discussed. Angle HD, for the example depicted is 0.5° and maybe varied as previously described.

In FIG. 38, an outlet end view of the shell 360 is depicted, withsupport grid 370, comprising strips 371, being viewable.

FIG. 39 is an end elevational view of shell 360, generally taken towardopen end 430. Here, the opposite sides 354, 355, with outer flanges 358,359, respectively, are viewable.

In FIG. 40, an enlarged fragmentary view of a selected portion of FIG.39 is shown. Flange 359 is viewable positioned and configured to define,gap 390. Some example dimensions for an example system are provided asfollows: IA=14 mm; IB=33 mm; IC=12 mm; and, ID=16.5 mm. Of course thedimensions can be varied.

In FIG. 41, a second plan view, analogous to FIG. 38, is provided. Anexample dimension is indicated as follows: JA=258 mm.

In FIG. 42, a cross-sectional view generally taken along line 42-42,FIG. 41, is provided. In FIG. 42A, an enlarged fragmentary view of aportion of 42 is provided. Here a cross-section of one of joint 435 ofstrips 371 is viewable. An indicated angle is as follows: −KA=1°.

In FIG. 43, an enlarged fragmentary view of an identified portion ofFIG. 41 is shown; the portion depicted comprising a joint 435 of strips371. Some example dimensions are provided in FIG. 43 as follows: LA=2.3mm; LB=10.8 mm diameter; LC=6.5 mm diameter.

FIG. 44 is an enlarged fragmentary view of an identified portion of FIG.41. Apertures 440 are depicted. In general, referring to FIG. 41,apertures 440 extend along base regions 442, 443 at opposite open ends430, 431.

In FIG. 44, some example dimensions are provided as follows: MA=3 mm;MB=8 mm; and, MC=1.5 mm radius.

Manufacture of example cartridge 302 using shell 360 would generally beas follows. The shell 360 would be pre-formed, for example molded from aplastic. A blocked, stacked, media pack 330 of appropriate size would beformed, for example from strips of single facer and, for example,generally in accord with descriptions above for FIGS. 1-6. The mediapack 330 would be inserted into interior 446 of shell 360, FIGS. 34 and35. The media pack 330 would be positioned with an inlet face adjacent331 flanges 358, 359, and an outlet face 332 adjacent (facing) supportgrid 370.

Sealant would be positioned in gaps 390, 391, FIG. 29, between theflanges 358, 359 and the media pack 330, adjacent end face 331. Thissealant would seal against air flow around the media pack 330 betweenthe opposite sides 354, 355 of the shell 360.

Referring to FIG. 36, the opposite open ends 430, 431 of the shell 360,and opposite ends 334, 335 of the media pack 330 (FIG. 19) adjacent theends (430, 431) of the shell 360 would be potted in molded-in-place endpieces corresponding to end pieces 352 a, 353 a, FIG. 15, respectively.These molded-in-place pieces will typically comprise molded-in-place,foamed, polyurethane. The polyurethane will preferably be molded to anas molded density of no greater than 30 lbs/cu. ft. (0.46 g/cc),typically no greater than 15 lbs/cu. ft. (0.24 g/cc) and sometimes nogreater than 10 lbs. cu. ft. (0.16 g/cc); and, a hardness Shore A of nogreater than 30, typically no greater than 25 and often within the rangeof 12-20, inclusive. A similar material can be used for seal material341.

It is noted that during the molding of end pieces 352 a, 353 a the resinwill be allowed to flow through apertures 440, to provide for amechanical connection.

In a final step of assembly, projection arrangement 375 will be insertedin a mold containing resin appropriate for molding in place seal member365. Such a seal member, for example, can comprise a foamed polyurethanegenerally as characterized above.

It is noted that an alternate specific order of steps could beconducted.

E. Selected Further Detail Regarding the Housing End Wall 349, Aperture348, and a Safety Cartridge

In FIG. 45, an inside perspective view of end wall 349 and aperture 348is viewable. In FIG. 46, an inside plan view is shown, with seal groove350 shown in cross-hatch lines.

In FIG. 47, an outside view of end wall 349 is provided.

In FIG. 48, a perspective view of a frame member 450 for a safetycartridge 451, FIG. 49, is depicted. Typically, the example frame member450 will include an outer frame 452 having strengthening extensions 453extending thereacross. The particular frame member 452 depicted,comprises opposite curved ends 455, 456 with a pair of opposite sides457, 458 extending therebetween. In a typical safety cartridge, apleated media pack, not shown, would be positioned within frame 430.

The frame member 450 is provided with a seal member 460 extendingtherearound.

Referring to FIG. 49, a side elevational view of safety cartridge 451 isprovided. with seal member 460 extending therearound. The seal member460 defines an outwardly projecting, slanted surface 461, taperingdownwardly toward side 465 of frame 450 from an edge toward side 466.Typically, safety cartridge 451, comprising a frame piece 450 and mediatherein, would be pushed into a seal location, in the direction of arrow467.

Referring back to FIG. 45, the safety cartridge 451 is sized andconfigured to be inserted into (or over) outlet aperture 348, with sealmember 460 engaging side wall 348 s of aperture 348. Aperture 348includes end stop 348 x, to provide an end stop to insertion of safetycartridge 451.

It is noted that air cleaner assembly 300 could be used without a safetycartridge, and could be configured for use with an alternate safetycartridge. Indeed, in some instances, the air cleaner assembly 300 canbe configured with a second groove, analogous to seal groove 350,configured to receive seal member generally analogous to a seal member365, on a safety cartridge.

F. Certain Problems Addressed by the Features Characterized Above

The features characterized above, relate to the addressing a number ofissues concerning filter assemblies using fluted media extending betweenopposite and inlet and outlet flow faces, for example fluted mediacomprising a stack of strips; each strip comprising a single facer stripof fluted media secured to a facing sheet with appropriate sealing. Inmany prior systems, housing seal arrangements used stacked media packscomprising radial flanges configured to be pinched, axially, betweenhousing sections. On the other hand, radial type seals have also beenused, see for example WO 2004/071616 incorporated herein by reference.In contrast, at least preferred applications of systems according to thepresent disclosure relate to the presentation of a radial type seal andframe in which the seal is compressed within a housing groove, from bothsides.

Although the previously described figures depict a metal assembly for ahousing, it is anticipated that typically the housing will be a moldedplastic unit. When molded plastic housings are used, there can beproblems with deformation, during plastic molding, of certain features.When those features are designed to operate as sealing surfaces,deformation can be a problem. Especially when the sealing surfaces areextended straight surfaces, any deformation can cause a problem in sealintegrity, when the deformation occurs in a surface against which a sealis to be formed. This is a problem as the length of the straight housingsurface, against which a cartridge seal is to be pressed when installed,exceeds about 6 inches (152 mm) and is exacerbated at increasinglengths, for example 10 inches (254 mm) or greater.

Of course, air cleaner housings typically have covers that open foraccess to the cartridge. A common practice is to use a pinch seal gasketfor this type of application. However, a pinch seal that relies on acover to close and compress the gasket is vulnerable to the tolerancesof the closure fit and the reliability of the closure to maintaincompression when the assembly experiences shock and vibration forces.

To address the limitation of pinch type seals, radial seals have beendeveloped; however these have most often been implemented in coiledarrangements, although they have been depicted for other units, see WO2004/071616, referenced above. With coiled arrangements sealing isagainst round housing surfaces involved, which is not as subject toundesirable levels of deformation during cooling, as are relatively longstraight housing surfaces.

Thus, the problem of developing a housing surface which is desirable foruse as a housing seal surface for engagement by the compressive forcesof a radial seal, is exacerbated as the surface needs to be straight;and, is further exacerbated as the surface needs to be long.

Radial seals rely on a substantial amount of compression maintainedbetween the seal frame and side walls of the housing. In order for theseal to be maintained, the walls of the air cleaner housing need to havea substantial structural construction to prevent the side walls of thehousing from bowing out from the compression forces and losing the forceneeded to maintain the seal.

Additionally, radial seals are sensitive to the dimensional tolerancesof the seal frame and housing components, to maintain the properdimensions for seal compression. These tolerances are typicallyproportional to the overall dimension of the parts, and, again, becomemuch more problematic with largest component sizes.

The type of seal, involving a seal member directed into a seal groove,of a double sided gasket on the housing seal member, as described above,especially in connection with the FIG. 30 provides the followingattributes.

First, the gasket seal is accompanied by radial forces that are notdependent on closure fit when an air cleaner cover made to the housing.This allows for modification in closure engagement shape, for convenientopening and access with respect to the equipment with which the aircleaner is to be used.

A seal arrangement with compressive forces against opposite sides,imposes opposite forces on the side walls of the groove. The need forsubstantial structural construction of the housing is reduced, since theradially directed seal forces are contained within a narrow channel of agroove.

Seal face to seal face dimension of the groove can be maintained to amuch tighter tolerance, because the relative dimensions are relativelysmall. This is by comparison to the dimension entirely across an outerperiphery of a seal member.

For the particular example depicted, the groove seal provides twodistinct, opposite, seal faces. Alternatives are possible, as will beunderstood from certain each of the embodiments described below.

The seal support for a groove seal of the type characterized above, isintended to have as certain structural characteristics:

-   -   (a) A rigid beam strength in the axis that imposes the force to        insert the gasket into the groove. This is to ensure that the        gasket is fully inserted in the groove.    -   (b) A pliable, or flexible, beam strength when the axis is        perpendicular to the beam, where side to side sealing forces are        imposed. This is to enable the gasket to conform to manufacture        deformation variability in the side walls of the housing groove.        The seal frame is intended to be allowed to “float” in this axis        and to rely on the gasket sealing forces to center it in the        groove of the air cleaner housing.

Alternately stated, seal supports of projection 375 are built to besomewhat flexible in directions perpendicular to the length of thesupports. This flexibility can be provided by: the selected materialfrom which the shell portion 375 is made; the selected thickness of theshell portion 375 in a direction between opposite sides thereof; and,the configuration of the shell portion 375, which allows forflexibility.

In general, with a media pack comprising strips of media, the media packconfiguration will typically be a blocked, stacked, rectangular squareconfiguration. Typically, as a result, a convenient seal perimeter shapewill be one with a first pair of opposite sides and second pair ofopposite sides, typically comprising a square or rectangular shape withthe sides being straight. With such a configuration, it is desirablethat: the seal support embedded in the seal member has a first pair ofopposite (typically straight) sides; and, a second pair of opposite(typically straight) sides (ends); with corners between the adjacentsides being open, i.e. not bridged or connected for strength. This meansthat the individual sides of the seal support can flex somewhat,independently of one another. It is further desirable that various sidesof the seal support embedded within the seal material are not supportedby gussets or struts, to inhibit flexing. To facilitate flexing alongthe length of each of the seal support sides, the various sides of theportion of the seal support embedded within the seal member, areconfigured with gaps therein, i.e. each side includes tabs. This isparticularly desirable on longer sides, especially ones exceeding about10 inches (254 mm) in length, however, it can be used for shorter sidesalso, as shown.

IV. Some Alternate Embodiments A. A First Alternate Embodiment, FIGS.50-54

In FIGS. 50-54, a first alternate embodiment for a filter cartridgeusable with the housing 301 is depicted.

Attention is first directed to FIG. 50, a side elevational view ofcartridge 500. Cartridge 500 would include a media pack analogous tomedia pack 330, discussed above. Air flow through cartridge 500, duringfiltering, would be in the general direction of arrow 501. Thus, theenclosed media pack 330 would have an inlet face 331 and outlet flowface 332. Cartridge 500 includes a shell 504 extending between open(side) ends 505, 506, the open ends 505, 506 being closed bymolded-in-place side pieces 510, 511, respectively.

The shell 504 includes a first side 513 with ribs 514 thereon, and,typically an analogous second opposite side to side 513.

Housing seal arrangement 517 projects outwardly in a direction of airflow away from outlet end face 332. The housing seal arrangement 517differs from the housing seal arrangement 340 for cartridge 302. Inother manners, however, cartridge 500 is generally analogous tocartridge 302.

Attention is now directed to FIG. 51, an end elevational view takentoward side piece 510.

Comparing FIGS. 50 and 51, it can be seen that an outer surface 521 ofhousing seal member 518 of housing seal arrangement 517 comprises aplurality of spaced sections 522, the sections 522 being spaced by gaps523. Thus, outer surface 521 is not configured to form a housing seal.However the inner surface, not viewable in FIGS. 50 and 51, of housingseal arrangement 517 will generally be analogous to surface 402, FIG.30, and would form an inwardly directed radial seal within groove 350.

Tab sections 522 will, however, press against an outer wall 396 of thegroove 350, FIG. 33, providing for compression against the housing sealmember 517 by both groove sides 395 and 396. This will ensure thatsufficient compressive force is present, for forming the inwardlydirected radial seal. However, the sections 522, with gaps 523, can beused to reduce the insertion and withdrawal force for the cartridge 500,with respect to the housing seal groove 350. It is noted that outersurface 521 can be provided with a cross-sectional configurationgenerally analogous to that of surface 401, FIG. 30. That is,longitudinal rib 525 can be present on inner surface 521; in this case,by comparison to FIG. 30, the rib 525 being discontinuous in extensionaround outer surface 521 of housing seal arrangement 517.

In FIG. 52, cross sectional view taken along line 52-52, in FIG. 50 isprovided. Grid 525, comprising strips 526 is viewable, against outletflow face 332 of media pack 330. Further, the shell 504, and thus thecartridge 500, can be seen to have outwardly directed flanges 530,531,analogous to flanges 358, 359.

FIG. 53 is a plan view taken generally toward face 332.

FIG. 54 is an enlarged fragmentary view of an identified portion of FIG.52. In FIG. 54, some example dimensions are shown as follows: NC=2-20mm; NB=2-20 mm. Indeed, for the particular example depicted in FIG. 54,the seal material sections 522 overlap tabs 366, and the seal materialgaps 523 overlap gaps 377.

In sum, then, cartridge 500 is generally analogous to cartridge 302, andcan be manufactured in analogous manner. The basic difference relates tothe outside surface of the housing seal member which is continuous forcartridge 302, and which is discontinuous for cartridge 502, see surface521. This means the seal will not be formed against outer surface 396 ofgroove 350, FIG. 30, when cartridge 500 is installed, in contrast tocartridge 302. However spaced sections 522 in outer surface 521 willensure that a compressive contact with outer surface of groove 350 isgenerated, to ensure a cross-sectional compression against housing sealarrangement 517. This will ensure a seal against inner surface 397 ofgroove 350.

It is noted that in the particular example cartridge 500, and inparticular the housing seal arrangement 517, the various corners 528 ofthe housing seal arrangement 517 are continuous sections of sealmaterial.

It is noted that in an alternate application of the techniques describedwith respect to FIGS. 50-54, an inner surface of the housing sealarrangement could be made discontinuous while the outer surface,corresponding to surface 521, would be made to be a continuous sealsurface. In this instance, the housing seal would form against the outersurface 396 of the groove; and, the inner surface 397, of the groove 350would be engaged by a discontinuous seal material provide compressionwithin the groove 350, for operation of the seal.

Typically, if only one of the opposite surfaces of the seal member isconfigured to form a seal, within the groove 350, it will be preferredto select the radially inner surface to form that seal. A reason is thatduring shipping and handling, radially inwardly directed seal surfacesare more protected against damage. Also restriction forces against themedia pack may tend to cause a restriction in the seal area, which willoperate in favor of an inwardly directed radial seal.

B. A Second Alternate Cartridge Embodiment, FIGS. 55-57

A second alternate embodiment of a cartridge is depicted in FIGS. 55-57.Referring first to FIG. 57, an alternate cartridge usable in housing 301is indicated at reference numeral 540. Cartridge 540 is generallyanalogous to cartridge 302, with one major change. That major change isthat projection 541, corresponding to projection 375, comprises solidstrips without gaps therein, except in the corners. Thus, projectionarrangement 541 comprises four strips without gaps, a pair of long,opposite, sides; and, a pair of short, opposite ends.

Referring to FIG. 55, then, cartridge 540 is depicted, comprising amedia pack 330 having opposite inlet and outlet flow faces, outlet face332 being viewable in FIG. 55. In general, the cartridge 540 includesshell 545 generally analogous to shell 360 except modified in aprojection region as discussed below. The shell 545 has opposite sides546, 547 with flanges 548, 549 thereon, and media pack 330 positionedtherebetween. Open ends 551, 552 is a shell 545 are closed bymolded-in-place end pieces 554, 555 respectively.

In FIG. 56, a cross-sectional line taken along line 56-56, FIG. 55, isprovided of cartridge 540. Here media pack 330 can be seen with inletflow face 331 and opposite outlet flow face 332. The housing sealarrangement 555 is viewable, comprising a seal member 556 positioned inplace over projection arrangement 541 on shell 545. Projectionarrangement 541, again, comprises continuous strips (without gaps exceptin corners) projecting away from outlet flow face 332, the projectionarrangement 541 comprising four strips with open corners. By “open” inthis and related context, herein, with reference to corners, it is meantthat the plastic material of projection arrangement 541 includes a gaptherein, in each of the four corners. This means that each of the fourstrips is independent of the other four strips and can flexindependently. This prevents adjacent strips from operating tostrengthen or make more rigid, various strips of projection arrangement541. Preferably, each of the four strips of the projection arrangement541 terminates short of turning into the corner, so that corner turns donot provide strengthening or rigidity, resisting flexing of acorresponding strip.

In FIG. 57, an enlarged fragmentary view of a selected portion of FIG.56 is depicted. In FIG. 57, an open corner 560 in projection arrangement541 can be seen.

The particular embodiment of FIGS. 55-57 can be configured with amolded-in-place seal member 556 having a configuration analogous to sealmember 365 FIG. 30, i.e., with both an inner projecting rib or an outerprojecting rib. Further it can be implemented with the seal memberconfiguration of the embodiment of FIGS. 50-54, i.e., with a continuousseal on one side, but a plurality of spaced projections on the sealmaterial on the opposite side, to form a seal against only one of thetwo side surfaces of housing groove 350, while being compressed againstan opposite surface.

It is noted that the embodiment of FIGS. 55-57 will not have as muchflexibility as housing seal arrangement of earlier describedembodiments; and, thus. may not be as preferred with respect tomanufacturing tolerances, in the larger sizes. However madeappropriately thin, projection arrangement 541 will exhibit some flexalong its length, especially in the presence of the open corners.

C. A Third Alternate Embodiment, FIGS. 58-67

In FIGS. 58-67, a third alternate embodiment of a cartridge usable inthe housing 301 is discussed. Referring first to FIG. 58, cartridge 570is generally viewable. A particular difference in cartridge 570, frompreviously described cartridges, is that no shell is used as a preform.

Referring to FIG. 58, cartridge 570 comprises a media pack 330 extendingbetween an inlet flow face 331 an opposite outlet flow face 332. Themedia pack 330 is not positioned in a preform shell. Rather, the mediapack 330 is positioned between two side panels 571, 572. The side panelscan comprise fiber board, plastic sheet or other material, as selected.The side panels 571, 572 are secured in place by: molded-in-place endpieces 575, 576, which also seal closed opposite ends 578, 579 of mediapack 330; and, strips of sealant which would at least be positionedalong edges 571 x, 572 x, between side panels 571, 572 and media pack330.

For the embodiment cartridge 570, each of the side panels 571, 572 andend pieces 575, 576 is configured to extend beyond outlet flow face 332sufficiently far, to provide a projection arrangement or support forhousing seal member 583. This is discussed further below in connectionwith other drawings. It is noted that with such a configuration, thefour corners 584 of the housing seal arrangement 583 will have gaps inthe embedded support for seal material 586.

FIG. 59 is a side elevational view of cartridge 570 generally directedtoward side panel 572.

FIG. 60 is a cross sectional view taken along generally line 60-60 ofFIG. 59. Here the media pack 330 can be seen extending between inletflow face 331 and outlet flow face 332. Further, end sections 571 y, 572y of the panels 571, 572 can be seen projecting outwardly from flow face332 in an axial direction, away from media pack 330.

Further, housing seal arrangement 583 can be seen as includingmolded-in-place seal material 586, on a frame defined by portions 571 y,572 y of the side panels 571, 572, projecting axially beyond end face332 in a direction away from the media pack 330.

FIG. 64 is an enlarged fragmentary view of a portion of FIG. 60. Hereportion 571 y of side panel 571 can be seen with a portion of housingseal arrangement 583, and in particular a seal member 586 thereof,molded-in-place. The particular seal member 586 has an outer side 587and an inner side 588, each of which has a central longitudinal rib, 587x, 588 x. Of course the seal member 586 could be configured in accordwith alternatives described previously, such as to have only innersurface 588 configured for a seal surface, or only surface 587configured as a seal surface, when the opposite surface to seal surfaceis discontinuous, with spaced sections therein.

FIG. 61 is a plan view of cartridge 570 taken generally toward outletflow face 332 of media pack 330. Housing seal arrangement 583 can beseen as extending in a rectangular pattern, in at least partial andoverlap with perimeter portions of outlet flow face 332.

FIG. 62 is a cross sectional view of FIG. 61, taken along line 62-62thereof. Here an extension 575 x of panel 575 can be seen, extendingbeyond outlet flow face 332 of media pack 330. A portion of sealmaterial 586 is molded-in-place with portion 575 x projecting therein.

FIG. 63 is an enlarged fragmentary view of an identified portion of FIG.62. Section 575 x is more readily viewable. It is noted that a portionof region 575 x, indicated generally at 590, is embedded within sealmember 586.

FIG. 65 is an end elevational view of cartridge 570, generally directedtoward end member 575.

FIG. 66 is a cross-sectional view taken generally along line 66-66, FIG.65. Here extensions 575 x 576 x, respectively, of end pieces 575, 576are viewable, extending axially beyond face 332 of cartridge 302, in adirection away from the cartridge 302.

FIG. 67 is an enlarged fragmentary view of a portion of FIG. 66.

In general, then, the seal arrangement of cartridge 570, FIGS. 58-67, isformed from a molded-in-place seal member 586 positioned on extensionsof the side pieces 575, 575, and the side panels 571, 572.Molded-in-place end pieces 575, 576, then, will typically be made from aharder material than used for end pieces of the earlier describedembodiments also provide support and for the seal member 586.

Of course the embodiment of FIG. 58 could be implemented with thevariations in one of the two seal material surfaces, describedpreviously; i.e. either the outer surface of the inner surface could bediscontinuous, with the seal only formed against a selected one of thesides of groove 350.

Flexibility in the sides of the support embedded within seal material586, for the embodiment of FIGS. 58-67 is provided by the following:gaps in the corners; and, choosing the material for the side panels 571,572, and the end pieces 575, 576, to provide for some flexibility.

It is noted that the housing seal arrangement 583 of the cartridge 570,FIGS. 58-67, is not positioned as much in axial overlap with surface332, as is the housing seal arrangement for the other embodiments. Thus,the media pack 330 of FIG. 58 may have slightly smaller outer perimeterdimensions, for the same size sealing groove in the housing.

V. General Comments

According to the present disclosure, various filter cartridges, featuresthereof, and air cleaner assemblies and features thereof are described.There is no specific requirement than an air filter cartridge or aircleaner include all of the features characterized herein, in order toobtain some benefit of the present disclosure.

According to one aspect of the present disclosure, an air filtercartridge is provided that includes a media pack having opposite inletand outlet flow faces. The media pack comprises fluted media havingflutes extending in a direction between inlet and outlet flow faces.Typically, the media pack typically comprises a stack of strips offluted media having flutes extending in a direction between the inletand outlet flow faces; and, in a specific media pack characterizedherein, the media pack comprises a stack of strips of single facer; eachstrip of single facer comprising a sheet or strip of a fluted media,having flutes extending in a direction between the inlet and outlet flowfaces, secured to a sheet (strip) of facing media.

In general, the media pack is closed to flow of air entering the inletface and passing outwardly from the outlet flow face, without filteringflow through media of the media pack.

The cartridge includes a housing seal arrangement positioned to projectfrom adjacent the outlet flow face and configured with a seal memberhaving: a radially inwardly directed housing seal groove engagementsurface; and, a radially outwardly directed housing seal grooveengagement surface. At least one of the radially inwardly directedhousing seal groove engagement surface and the radially outwardlydirected housing seal groove engagement, has a housing seal surface. Inan example described herein, both the radially inwardly directed housingseal groove engagement surface and the radially outwardly directedhousing seal groove engagement surface, are housing seal surfaces. In analternate embodiment described herein, one of the radially inwardlydirected housing seal groove engagement surface and the radiallyoutwardly directed housing seal groove engagement surface is a sealsurface, and the other housing seal groove engagement surface isconfigured to engage the groove, for example with spaced tabs ofcompressible seal material, in manner that does not form a continuoushousing seal with the housing seal groove.

In example arrangements described herein, the inner groove engagementsurface has a central, longitudinal, rib; and, the outer grooveengagement surface face has a central, longitudinal, rib. At least oneof the ribs is a seal rib. In an arrangement with two opposite sealfaces, each face has a central, longitudinal, seal rib which iscontinuous.

In typical arrangements characterized herein, the housing sealarrangement includes a seal member having a perimeter shape with firstand second, opposite, straight sides; and, first and second, opposite,straight ends. The corners (4) typically are rounded.

In certain selected embodiments described herein, the housing sealarrangement comprises a frame projection having seal material thereon.The frame projection of such arrangements typically comprises a pair offirst and second, opposite, sides; a pair of first and second, opposite,ends; and, four open corners. By the term “open corners” as used herein,it is meant that the sides do not abut or engage one another adjacentthe corners. Typically, each corner has an opening at least 2 mm deep,typically at least 2-15 mm deep, inclusive (usually 5-15 mm deep,inclusive) although alternatives are possible. Also, typically each ofthe frame projection sides is provided without a gusset or other supportmember, enhancing rigidity of the frame projection sides.

In an example arrangement characterized herein, the first and second,opposite, sides each have a first length L₁; and, the first and second,opposite, ends each have a length of L₂; with L₁ greater than L₂.Typically L₁ is at least 50 mm greater than L₂, usually at least 80 mmgreater than L₂.

In example arrangements characterized generally herein, L1 is typicallyat least 200 mm, usually at least 250 mm, and often 300 mm or more; and,L2 is typically at least 150 mm, usually at least 200 mm, and often 230mm or more.

In a typical arrangement herein, at least each extension (side or end)of the frame projection which is greater than about 6 inches (152 mm)long, often comprises a plurality of spaced tabs. In a typical assembly,this generally comprises at least the first and second, opposite, sides.

In some assemblies characterized herein, each of the first and second,opposite sides and the first and second, opposite, ends of theprojection comprises a plurality of spaced, tabs whether greater than 6inches (152 mm) in length or not. Typically, each tab within the frameprojection has: a width within in the range of 2-20 mm, inclusive,usually 5-20 mm, inclusive; and is spaced from at least one adjacent bya tab by a distance within the range of 2-20 mm, inclusive, usually atleast 5 mm; although alternatives are possible. Also, typically each tabhas a length within the range 2-15 mm, inclusive, usually at least 5 mm,although alternatives are possible.

In certain example assemblies characterized herein, the air filtercartridge includes a preform shell; the preform shell having: a firstand second, opposite, sides; an open inlet end; an outlet end; and firstand second, opposite, open (side) ends. In an example, a preform shellis provided which includes flanges projecting outwardly from each of thefirst and the second, opposite, sides in a direction generally away fromadjacent portions of the preform. Also, a preform is characterizedherein which includes support grid, extending across the outlet end.

Typically a media pack is positioned within the preform with: an outletflow face of the media pack adjacent the outlet end of the preformshell; and, the inlet flow face of the media pack adjacent the inlet endof the preform shell. The media pack is typically positioned between thefirst and second, opposite, sides of the preform shell with thecartridge further including first and second end panel pieces positionedto close the first and second, opposite, open (side) ends (not the inletand outlet ends) of the preform shell and to close opposite ends of themedia pack. Typically, the end panels or pieces are molded-in-place.

In certain example assemblies characterized herein, the preform shellincludes a (frame) projection surrounding the outlet end and projectingin a direction away from the media pack outlet face. Also, the housingseal arrangement includes the seal member positioned on the frame sealprojection. Typically, a seal member comprises molded-in-place sealmaterial, with a frame seal projection embedded therein.

In a alternate characterization of a filter cartridge described herein,the air filter cartridge comprises a media pack generally in accord withcharacterizations or selected ones of the characterizations providedherein above. A housing seal arrangement is configured to projectoutwardly from adjacent the outlet flow face of the media pack, in adirection away from an inlet flow face of the media pack. The housingseal arrangement includes a projection comprising: a pair of first andsecond, opposite, sides; a pair of first and second, opposite, ends;and, four open corners. The housing seal arrangement includes a sealmember positioned on the projection. The seal member is typicallyconfigured to have a continuous, rectangular, seal configuration withrounded corners and with at least one of: a first radially inwardlydirected seal face; and, a second radially, outwardly, directed sealface. An example arrangement has both radially inwardly and radiallyoutwardly, directed, continuous, seal faces; the seal arrangement beingrectangular with four rounded corners. A preform shell, as previouslycharacterized, can be used in the filter cartridge.

According to yet another characterization of the present disclosure, anair filter cartridge is provided which includes a media pack asgenerally characterized. Further, the cartridge includes a preform shellhaving: first and second, opposite, sides; and, first and second,opposite, (side) ends. The media pack is positioned between the firstand second, opposite, sides of the preform shell. First and second,opposite, side pieces are provided, typically molded-in-place, to: closethe first (side) open end of the preform shell and to close the firstend of the media pack; and, to close the second (side) open end of thepreform shell and to close the second end of the media pack. A housingseal arrangement is positioned, typically in at least partial overlapwith the outlet flow face of the media pack, and in any event, generallyprojecting in a direction away from the media pack. The housing sealarrangement comprises a seal member defining at least one of an inwardlydirected radial seal and an outwardly directed radial seal. The housingseal arrangement can be as characterized herein above.

Also according to the present disclosure, an air cleaner assembly isprovided which includes a housing having a housing body and an openableaccess cover. The housing includes an air flow inlet arrangement and anair flow outlet arrangement. The housing body includes a seal groovetherein having: a inner wall; and, a outer wall opposite the inner wall.The seal groove typically has a channel width with of least 8 mm and notgreater than 25 mm, typically 9-18 mm, inclusive, although alternativesare possible. This would correspond to a width between the inner walland the outer wall.

An air filter cartridge generally in accord with the previouscharacterizations, or selected portions of the previouscharacterizations, is typically positioned in a housing with the housingseal arrangement projecting into the seal groove and engaging each oneof the inner and outer walls of the seal groove. In some arrangements, aseal is formed against each of the inner and outer walls of the sealgroove; whereas in others, although each groove side wall is engaged,only one wall is engaged by a continuous seal.

In an example assembly depicted, the housing is configured for air flowthrough the inlet arrangement to be in an opposite direction to air flowthrough the outlet arrangement. Also, in an example arrangementdescribed, the access cover is hingedly mounted on the housing. In aspecific example depicted, the access cover is hingedly mounted forpivoting between an upper, closed, orientation, and a lower, open,orientation.

In an example characterized herein, the access cover includes a lockarrangement thereon, positioned to be engage a portion of the cartridge;for example, a flange arrangement on the cartridge, to help retain anenclosed filter cartridge in a sealed orientation, when installed. Incertain air cleaner assemblies according to the present disclosure, asecondary or safety cartridge can be positioned downstream of the mainfilter cartridge or filter cartridges as characterized above.

According to another aspect of the present disclosure, a filtercartridge is provided comprising a media pack having opposite inlet andoutlet flow faces. The media pack typically comprises a stack of stripsof fluted media having flutes extending in a direction between the inletand outlet flow faces. The media pack is closed to flow entering theinlet face and passing outwardly from the outlet face without filteringflow through media of the media pack.

The filter cartridge includes a housing seal arrangement positioned toproject from adjacent the outlet flow face and configured with a sealmember having at least one radially directed housing seal surface. Thehousing seal arrangement comprises a frame projection having sealmaterial thereon configured to form the housing seal surface. The frameprojection comprises a portion of a pre-formed shell having: first andsecond, opposite, sides; an outlet end; and an opposite inlet end. Itfurther includes first and second, opposite, open side ends; and, firstand second, opposite, outwardly directed flanges on the first and secondsides of the pre-formed shell adjacent the inlet end of the pre-formedshell and directed toward the inlet face of the media pack.

The cartridge further includes first and second end panels molded inplace: to close the first and second, opposite, open side ends to thepre-formed shell; and, to close opposite ends of the media pack.

In an example depicted, the media pack is positioned between theoutwardly directed flanges. The housing seal surface can comprise aradially outwardly directed seal, although alternatives are possible.

There is no specific requirement that an assembly, component ortechnique have all of the details characterized herein, in order toobtain some benefit according to the present disclosure.

1-20. (canceled)
 21. An air filter cartridge comprising: (a) a mediapack having an inlet flow face, and, an opposite outlet flow face andcomprising fluted media secured to facing media; (i) the media packbeing closed to air entering an inlet face and passing outwardly from anoutlet flow face without filtering flow through media of the media pack;and, (b) a housing seal arrangement comprising a seal member defining atleast one of an inwardly directed radial seal and an outwardly directedradial seal; (i) each such radial seal being a seal configured toprovide seal forces directed generally orthogonal to a direction of airflow through the media pack; and, (ii) a seal frame projection embeddedwithin the seal member; (A) the seal frame projection comprising aplurality of spaced tabs, having gaps between the tabs, embedded in theseal member.
 22. An air filter cartridge according to claim 21 wherein:(a) the media pack has a rectangular shape.
 23. An air filter cartridgeaccording to claim 21 wherein: (a) each tab has a width within the rangeof 2-20 mm inclusive.
 24. An air filter cartridge according to claim 21wherein: (a) each tab is positioned spaced from at least one adjacenttab by a distance within the range of 2-20 mm, inclusive.
 25. An airfilter cartridge according to claim 21 wherein: (a) each tab has a widthwithin the range of 2-20 mm inclusive; and, (b) each tab is positionedspaced from at least one adjacent tab by a distance within the range of2-20 mm, inclusive.
 26. An air filter cartridge according to claim 25wherein: (a) each tab has a length within the range of 2-15 mm,inclusive.
 27. An air filter cartridge according to claim 21 wherein:(a) each tab is located in a straight portion of the seal frameprojection.
 28. An air filter cartridge according to claim 27 wherein:(a) the portion of the seal frame projection comprising the spaced tabshas a rectangular shape.
 29. An air filter cartridge according to claim28 wherein: (a) the portion of the seal frame projection comprising thespaced tabs has a rectangular shape with four sides, each of which has alength of at least 152 mm.
 30. An air filter cartridge according toclaim 29 wherein: (a) the portion of the seal frame projectioncomprising the spaced tabs has a rectangular shape including a second,shorter, pair of opposite sides, each having a length of at least 50 mmless than each of the first pair of opposite sides.
 31. An air filtercartridge according to claim 30 wherein: (a) the portion of the sealframe projection comprising the spaced tabs has a rectangular shapeincluding a second, shorter, pair of opposite sides, each having alength of at least 80 mm less than each of the first pair of oppositesides.
 32. An air filter cartridge according to claim 30 wherein: (a)each tab has a length of at least 5 mm.
 33. An air filter cartridgeaccording to claim 32 wherein: (a) each tab is spaced from each adjacenttab by at least 5 mm.
 34. An air filter cartridge according to claim 21wherein: (a) the media pack comprises a stack of strips; each stripcomprising a fluted sheet secured to a facing sheet;
 35. An air filtercartridge according to claim 34 wherein: (a) the media pack has ablocked, stacked, configuration.
 36. An air filter cartridge accordingto claim 35 wherein: (a) each tab has a length of at least 5 mm.
 37. Anair filter cartridge according to claim 36 wherein: (a) each tab isspaced from each adjacent tab by at least 5 mm.
 38. An air filtercartridge according to claim 21 wherein: (a) each tab is spaced fromeach adjacent tab by at least 5 mm.
 39. An air filter cartridgeaccording to claim 38 wherein: (a) each tab has a length of at least 5mm.
 40. An air filter cartridge according to claim 21 wherein: (a) eachtab has a length of at least 5 mm.
 41. An air cleaner arrangementcomprising: (a) a housing including: a housing body; and, an openeableaccess cover; (i) the housing including an air flow inlet arrangementand air flow outlet arrangement; (ii) the housing body including a sealgroove therein having: an inner wall; and, an outer wall opposite theinner wall; and, (b) an air filter cartridge in accord with at least oneof claims 20-40 operably positioned within the housing with the housingseal arrangement projecting into the seal groove and engaging each oneof the inner and outer walls of the seal groove.